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Abstract:

A self contained motor-powered disposable loading unit for use with a
robotic system configured to generate control systems therefor. The
disposable loading unit may contain a battery that is retained in a
disconnected position when the disposable loading unit is not in use and
is moved to a connected position when the disposable loading unit is
coupled to the robotic system to permit the motor to be selectively
powered thereby. Indicators may be supported on the disposable loading
unit to indicate when the axial drive assembly thereof is in a starting
position and an ending position. Another indicator may be provided to
indicate when the anvil assembly is in a closed position.

Claims:

1. A disposable loading unit for use with a remotely controllable system,
said disposable loading unit comprising: a cartridge assembly; an
elongated housing coupled to said cartridge assembly and configured for
operable attachment to an elongated shaft assembly for transmitting
control motions from a control portion of the remotely controllable
system; an axial drive assembly supported for selective axial travel
through said cartridge assembly from a start position to an end position
upon application of a rotary control motion thereto from said elongated
shaft assembly; a motor supported within said housing and operably
interfacing with said axial drive assembly to selectively apply said
rotary motion thereto; and a power source axially movable within said
housing from a disconnected position wherein said power source is
disconnected from said motor to at least one connected position wherein
said power source provides power to said motor.

2. The disposable loading unit of claim 1 wherein said axially movable
power source is configured for attachment to an axially movable control
member of the surgical instrument such that said power source is axially
moved from said disconnected position to one of said at least one
connected positions upon attachment to the control member.

3. The disposable loading unit of claim 2 wherein said cartridge assembly
further comprises an anvil assembly selectively movable between an open
position and a closed position upon application of a closing motion
thereto from said axial drive assembly.

4. The disposable loading unit of claim 3 wherein said disposable loading
unit further comprises: a first contact arrangement in said housing
communicating with said motor and configured for contact with said power
source when said power source is in a first one of said at least one
connected positions; and a second contact arrangement in said housing
communicating with said motor and configured for contact with said power
source when said power source is in a second one of said at least one
connected positions.

5. The disposable loading unit of claim 4 wherein when said power source
is in said first connected position, said power source is axially movable
to said second connected position upon application of an actuation motion
to said axially movable control member.

6. The disposable loading unit of claim 5 wherein when said power source
is in said second connected position, said motor powers said axial drive
assembly to apply said closing motion to said anvil assembly.

7. The disposable loading unit of claim 6 further comprising a third
contact arrangement in said housing communicating with said motor and
configured for contact with said power source when said power source is
in a third one of said at least one connected positions.

8. The disposable loading unit of claim 7 wherein when said power source
is in said third connected position, said motor drives said axial drive
assembly proximally to said end position within said cartridge assembly.

9. The disposable loading unit of claim 8 wherein said axial drive
assembly comprises: a drive beam operably coupled to said motor; and a
tissue cutting edge on said drive beam.

10. The disposable loading unit of claim 8 wherein said means for
stopping said motor from driving said drive assembly in said proximal
direction when said axial drive assembly encounters resistance that
exceeds a predetermined amount of resistance.

11. A surgical instrument comprising: a tool drive portion configured for
operable attachment to a portion of a robotic system for receiving
control motions therefrom; an elongated shaft coupled to said tool drive
portion; an axially movable control member operably supported within said
elongated shaft and being axially movable in response to actuation
motions applied thereto from said robotic system; and a disposable
loading unit comprising: a housing coupled to said elongated shaft; a
staple cartridge supported by said housing assembly; an axial drive
assembly supported for selective axial travel through said cartridge
assembly from a start position to an end position upon application of a
rotary motion thereto; a motor supported within said housing and operably
interfacing with said axial drive assembly to selectively apply said
rotary motion thereto; and a power source axially movable within said
housing from a disconnected position wherein said power source is
disconnected from said motor to a first connected position wherein said
power source provides power to said motor upon attachment to the control
member.

12. The surgical instrument of claim 11 wherein said cartridge assembly
further comprises an anvil assembly that is selectively movable between
an open position and a closed position upon application of a closing
motion thereto from said axial drive assembly.

13. The surgical instrument of claim 11 wherein said disposable loading
unit further comprises: a first contact arrangement in said housing
communicating with said motor and configured for contact with said power
source when said power source is said first connected position; and a
second contact arrangement in said housing communicating with said motor
and configured for contact with said power source when said power source
is in a second connected position.

14. The surgical instrument of claim 13 wherein when said power source is
in said first connected position, said power source is axially movable to
said second connected position upon application of an actuation motion to
said axially movable control member.

15. The surgical instrument of claim 14 wherein said axially movable
control member is operably coupled to a movable handle member movably
supported on said handle assembly.

16. The surgical instrument of claim 12 wherein said disposable loading
unit further comprises: a first contact arrangement in said housing
communicating with said motor and configured for contact with said power
source when said power source is said first connected position; and a
second contact arrangement in said housing communicating with said motor
and configured for contact with said power source when said power source
is in a second connected position such that said motor powers said axial
drive assembly to apply said closing motion to said anvil assembly.

17. The surgical instrument of claim 16 further comprising a third
contact arrangement in said housing communicating with said motor and
configured for contact with said power source when said power source is
in a third connected position.

18. The surgical instrument of claim 17 wherein when said power source is
in said third connected position, said motor drives said axial assembly
proximally to said end position within said cartridge assembly.

19. A surgical instrument comprising: a tool drive portion configured for
operable attachment to a portion of a robotic system for receiving
control motions therefrom; an elongated shaft coupled to said tool drive
portion; an axially movable control member operably supported within said
elongated shaft and being axially movable in response to actuation
motions applied thereto from said robotic system; and a disposable
loading unit comprising: a housing coupled to said elongated shaft; a
staple cartridge supported by said housing assembly; an axial drive
assembly supported for selective axial travel through said cartridge
assembly from a start position to an end position upon application of a
rotary motion t hereto; a motor supported within said housing and
operably interfacing with said axial drive assembly to selectively apply
said rotary motion thereto; a movable battery holder coupleable to said
control member and being axially movable within said housing in response
to motions applied thereto by a control rod; and a battery supported
within said battery housing and configured for selective axial
communication with a series of axially spaced contact arrangements in
said housing for controlling supply of power from said battery to said
motor.

20. The surgical instrument of claim 19 wherein said axially movable
control member is manually actuated by moving a movable handle member on
said handle assembly.

Description:

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This non-provisional application for patent is a
continuation-in-part patent application of U.S. patent application Ser.
No. 12/856,099, filed Aug. 13, 2010, U.S. Patent Publication No. US
2010/0301096 A1 which is a continuation patent application of U.S. patent
application Ser. No. 12/031,628, filed Feb. 14, 2008, now U.S. Pat. No.
7,793,812, the disclosures of which are herein incorporated by reference
in their respective entireties.

FIELD OF THE INVENTION

[0002] The present invention relates in general to endoscopic surgical
instruments including, but not limited to, surgical cutting and stapling
apparatuses that have disposable loading units that are capable of
applying lines of staples to tissue while cutting the tissue between
those staple lines and, more particularly, to improvements relating to
such disposable loading units.

BACKGROUND

[0003] Endoscopic surgical instruments are often preferred over
traditional open surgical devices since a smaller incision tends to
reduce the post-operative recovery time and complications. Consequently,
significant development has gone into a range of endoscopic surgical
instruments that are suitable for precise placement of a distal end
effector at a desired surgical site through a cannula of a trocar. These
distal end effectors engage the tissue in a number of ways to achieve a
diagnostic or therapeutic effect (e.g., endocutter, grasper, cutter,
staplers, clip applier, access device, drug/gene therapy delivery device,
and energy device using ultrasound, RF, laser, etc.).

[0004] Known surgical staplers include an end effector that simultaneously
makes a longitudinal incision in tissue and applies lines of staples on
opposing sides of the incision. The end effector includes a pair of
cooperating jaw members that, if the instrument is intended for
endoscopic or laparoscopic applications, are capable of passing through a
cannula passageway. One of the jaw members supports a staple cartridge
that has at least two laterally spaced rows of staples. The other jaw
member defines an anvil having staple-forming pockets aligned with the
rows of staples in the cartridge. The instrument commonly includes a
plurality of reciprocating wedges which, when driven distally, pass
through openings in the staple cartridge and engage drivers supporting
the staples to effect the firing of the staples toward the anvil.

[0005] One type of surgical stapling apparatus is configured to operate
with disposable loading units (DLU's) that are constructed to support a
staple cartridge and knife assembly therein. Once the procedure is
completed, the entire DLU is discarded. Such instruments that are
designed to accommodate DLU's purport to offer the advantage of a "fresh"
knife blade for each firing of the instrument. Examples of such surgical
stapling apparatuses and DLU's are disclosed in U.S. Pat. No. 5,865,361
to Milliman et al., the disclosure of which is herein incorporated by
reference in its entirety.

[0006] Such prior disposable loading units, however, require the clinician
to continuously ratchet the handle to fire the staples and cut the
tissue. There is a need for a surgical stapling apparatus configured for
use with a disposable loading unit that is driven by a motor contained in
the disposable loading unit.

SUMMARY

[0007] In one general aspect of various embodiments of the present
invention, there is provided a disposable loading unit for attachment to
a surgical cutting and stapling apparatus. In various embodiments, the
disposable loading unit may comprise a carrier that supports a staple
cartridge therein. An anvil assembly may be movably coupled to the
carrier for selective movable travel between open and closed positions
relative to the staple cartridge. An axial drive assembly may be
supported within the carrier such that it can move in a distal direction
from a start position to an end position through the carrier and the
staple cartridge. The axial drive assembly may also be retracted in a
proximal direction from the end position back to the start position. A
motor may be supported within the carrier and constructed to drive the
axial drive assembly in the distal and proximal directions. A battery may
be supported within the carrier and be coupled to the motor for supplying
power thereto.

[0008] In still another general aspect of various embodiments of the
present invention, there is provided a disposable loading unit for
attachment to a surgical cutting and stapling apparatus. In various
embodiments, the disposable loading unit includes a carrier that supports
a staple cartridge therein. An anvil assembly may be movably coupled to
the carrier for selective movable travel between open and closed
positions relative to the staple cartridge. A housing may be coupled to
the carrier and be configured for removable operable attachment to the
surgical stapling apparatus. An axial drive assembly may be supported
within the carrier and the housing to move in a distal direction from a
start position to an end position through the carrier and the staple
cartridge. The axial drive assembly may also be retracted in a proximal
direction from the end position to the start position. A motor may be
supported within the carrier and configured to interface with the axial
drive assembly to drive the axial drive assembly in the distal and
proximal directions. A battery may be supported within the carrier and be
coupled to the motor for supplying power thereto. The battery may be
selectively movable between a disconnected position and connected
positions in response to motions applied thereto by a portion of the
surgical stapling apparatus.

[0009] In another general aspect of various embodiments of the present
invention, there is provided a surgical cutting and stapling apparatus.
Various embodiments of the instrument may include a handle assembly that
operably supports a drive assembly therein that is constructed to impart
drive motions and a retraction motion. A movable handle portion may be
operably supported on the handle assembly and configured to interface
with the drive system such that manipulation of the movable handle causes
the drive system to impart the drive motions. An elongated body may
protrude from the handle assembly and have a distal end that is couplable
to a disposable loading unit. In various embodiments, the disposable
loading unit may comprise a carrier that has a staple cartridge supported
therein. An anvil assembly may be movably coupled to the carrier for
selective movable travel between open and closed positions relative to
the staple cartridge. An axial drive assembly may be supported within the
carrier such that the axial drive assembly may move in a distal direction
from a start position to an end position through the carrier and the
staple cartridge and also in a proximal direction from the end position
to the start position. A motor may be supported within the carrier and
configured to interface with the axial drive assembly to drive the axial
drive assembly in the distal and proximal directions. A battery may be
supported within the carrier and be coupled to the motor for supplying
power thereto. The battery may be configured to interface with a portion
of the elongated body to receive the drive motions therefrom upon
manipulation of the moveable handle.

[0010] In accordance with other general aspects of various embodiments of
the present invention, there is provided a disposable loading unit for
use with a remotely controllable system. In various embodiments, the
disposable loading unit comprises a cartridge assembly that has an
elongated housing coupled thereto that is configured for operable
attachment to an elongated shaft assembly for transmitting control
motions from a control portion of the remotely controllable system. The
disposable loading unit further comprises an axial drive assembly that is
supported for selective axial travel through the cartridge assembly from
a start position to an end position upon application of a rotary control
motion thereto from the elongated shaft assembly. A motor is supported
within the housing and operably interfaces with the axial drive assembly
to selectively apply the rotary motion thereto. A power source is axially
movable within the housing from a disconnected position wherein the power
source is disconnected from the motor to at least one connected position
wherein the power source provides power to said motor.

[0011] In accordance with yet other general aspects of various embodiments
of the present invention, there is provided a surgical instrument that
includes a tool drive portion that is configured for operable attachment
to a portion of a robotic system for receiving control motions therefrom.
An elongated shaft is coupled to the tool drive portion. An axially
movable control member is operably supported within the elongated shaft
and is axially movable in response to actuation motions applied thereto
from the robotic system. The surgical instrument further includes a
disposable loading unit that has a housing that is coupled to the
elongated shaft. A staple cartridge is supported by the housing assembly
and an axial drive assembly is supported for selective axial travel
through the cartridge assembly from a start position to an end position
upon application of a rotary motion thereto. A motor is supported within
the housing and operably interfaces with the axial drive assembly to
selectively apply the rotary motion thereto. A power source is axially
movable within the housing from a disconnected position wherein the power
source is disconnected from the motor to a first connected position
wherein the power source provides power to the motor upon attachment to
the control member.

[0012] In accordance with still other general aspects of various
embodiments of the present invention, there is provided a surgical
instrument that includes a tool drive portion that is configured for
operable attachment to a portion of a robotic system for receiving
control motions therefrom. An elongated shaft is coupled to the tool
drive portion. An axially movable control member is operably supported
within the elongated shaft and is axially movable in response to
actuation motions applied thereto from the robotic system. The surgical
instrument further includes a disposable loading unit that has a housing
that is coupled to the elongated shaft. A staple cartridge is supported
by the housing assembly and an axial drive assembly is supported for
selective axial travel through the cartridge assembly from a start
position to an end position upon application of a rotary motion t hereto.
A motor is supported within the housing and operably interfaces with the
axial drive assembly to selectively apply the rotary motion thereto. A
movable battery holder is coupleable to the control member and is axially
movable within the housing in response to motions applied thereto by a
control rod. A battery is supported within the battery housing and is
configured for selective axial communication with a series of axially
spaced contact arrangements in the housing for controlling supply of
power from the battery to the motor.

[0013] These and other objects and advantages of the present invention
shall be made apparent from the accompanying drawings and the description
thereof.

BRIEF DESCRIPTION OF THE FIGURES

[0014] The accompanying drawings, which are incorporated in and constitute
a part of this specification, illustrate embodiments of the invention,
and, together with the general description of various embodiments of the
invention given above, and the detailed description of the embodiments
given below, serve to explain various principles of the present
invention.

[0015]FIG. 1 is a perspective view of a disposable loading unit
embodiment of the present invention coupled to a conventional surgical
cutting and stapling apparatus;

[0016]FIG. 2 is a cross-sectional view of the disposable loading unit of
FIG. 1 with several components shown in full view for clarity;

[0017]FIG. 3 is a cross-sectional view of a proximal end of the
disposable loading unit embodiment of FIGS. 1 and 2 with various
components shown in full view for clarity;

[0018]FIG. 4 is a schematic of a circuit embodiment of the disposable
loading unit of FIGS. 1-3;

[0019] FIG. 5 is a cross-sectional view of the disposable loading unit of
FIGS. 1-3 when the disposable loading unit has been attached to the
elongated body of the surgical instrument;

[0020]FIG. 6 is a schematic view of the circuit illustrating the position
of various components of the disposable loading unit after it has been
attached to the surgical instrument;

[0021] FIG. 7 is a cross-sectional view of the disposable loading unit of
FIGS. 1-6 when the drive beam has been moved to the anvil closed
position;

[0022]FIG. 8 is a schematic view of the circuit illustrating the position
of various components of the disposable loading unit after the drive beam
has been moved to the anvil closed position;

[0023] FIG. 9 is a cross-sectional view of the disposable loading unit of
FIGS. 1-8 when the drive beam has been moved to its distal-most fired
position;

[0024] FIG. 10 is a schematic view of the circuit illustrating the
position of various components of the disposable loading unit after the
drive beam has been moved to its distal-most fired position;

[0025] FIG. 11 is a cross-sectional view of the disposable loading unit of
FIGS. 1-10 as the drive beam is being returned to a starting position;

[0026] FIG. 12 is a schematic view of the circuit illustrating the
position of various components of the disposable loading unit as the
drive beam is being returned to a start position;

[0027] FIG. 13 is a perspective view of one robotic controller embodiment;

[0028] FIG. 14 is a perspective view of one robotic surgical arm
cart/manipulator of a robotic system operably supporting a plurality of
surgical tool embodiments of the present invention;

[0029] FIG. 15 is a side view of the robotic surgical arm cart/manipulator
depicted in FIG. 14;

[0030] FIG. 16 is a perspective view of an exemplary cart structure with
positioning linkages for operably supporting robotic manipulators that
may be used with various surgical tool embodiments of the present
invention;

[0031] FIG. 17 is a perspective view of a surgical tool embodiment of the
present invention;

[0032] FIG. 18 is an exploded assembly view of an adapter and tool holder
arrangement for attaching various surgical tool embodiments to a robotic
system;

[0036]FIG. 22 is a partial bottom perspective view of the surgical tool
embodiment of FIG. 17;

[0037] FIG. 23 is a partial exploded view of a portion of an articulatable
surgical end effector embodiment of the present invention;

[0038]FIG. 24 is a perspective view of the surgical tool embodiment of
FIG. 22 with the tool mounting housing removed;

[0039]FIG. 25 is a rear perspective view of the surgical tool embodiment
of FIG. 22 with the tool mounting housing removed;

[0040]FIG. 26 is a front perspective view of the surgical tool embodiment
of FIG. 22 with the tool mounting housing removed;

[0041]FIG. 27 is a partial exploded perspective view of the surgical tool
embodiment of FIG. 26;

[0042] FIG. 28 is a partial cross-sectional side view of the surgical tool
embodiment of FIG. 22;

[0043]FIG. 29 is an enlarged cross-sectional view of a portion of the
surgical tool depicted in FIG. 28;

[0044] FIG. 30 is an exploded perspective view of a portion of the tool
mounting portion of the surgical tool embodiment depicted in FIG. 22;

[0045] FIG. 31 is an enlarged exploded perspective view of a portion of
the tool mounting portion of FIG. 30;

[0046]FIG. 32 is a partial cross-sectional view of a portion of the
elongated shaft assembly of the surgical tool of FIG. 22;

[0047] FIG. 33 is a side view of a half portion of a closure nut
embodiment of a surgical tool embodiment of the present invention;

[0048] FIG. 34 is a perspective view of another surgical tool embodiment
of the present invention;

[0049]FIG. 35 is a cross-sectional side view of a portion of the surgical
end effector and elongated shaft assembly of the surgical tool embodiment
of FIG. 34 with the anvil in the open position and the closure clutch
assembly in a neutral position;

[0050] FIG. 36 is another cross-sectional side view of the surgical end
effector and elongated shaft assembly shown in FIG. 35 with the clutch
assembly engaged in a closure position;

[0051] FIG. 37 is another cross-sectional side view of the surgical end
effector and elongated shaft assembly shown in FIG. 35 with the clutch
assembly engaged in a firing position;

[0052] FIG. 38 is a top view of a portion of a tool mounting portion
embodiment of the present invention;

[0053] FIG. 39 is a perspective view of another surgical tool embodiment
of the present invention;

[0054]FIG. 40 is a cross-sectional side view of a portion of the surgical
end effector and elongated shaft assembly of the surgical tool embodiment
of FIG. 39 with the anvil in the open position;

[0055]FIG. 41 is another cross-sectional side view of a portion of the
surgical end effector and elongated shaft assembly of the surgical tool
embodiment of FIG. 39 with the anvil in the closed position;

[0056]FIG. 42 is a perspective view of a closure drive nut and portion of
a knife bar embodiment of the present invention;

[0057] FIG. 43 is a top view of another tool mounting portion embodiment
of the present invention;

[0058]FIG. 44 is a perspective view of another surgical tool embodiment
of the present invention;

[0059]FIG. 45 is a cross-sectional side view of a portion of the surgical
end effector and elongated shaft assembly of the surgical tool embodiment
of FIG. 44 with the anvil in the open position;

[0060] FIG. 46 is another cross-sectional side view of a portion of the
surgical end effector and elongated shaft assembly of the surgical tool
embodiment of FIG. 45 with the anvil in the closed position;

[0061]FIG. 47 is a cross-sectional view of a mounting collar embodiment
of a surgical tool embodiment of the present invention showing the knife
bar and distal end portion of the closure drive shaft;

[0062]FIG. 48 is a cross-sectional view of the mounting collar embodiment
of FIG. 47;

[0063]FIG. 49 is a top view of another tool mounting portion embodiment
of another surgical tool embodiment of the present invention;

[0064]FIG. 49A is an exploded perspective view of a portion of a gear
arrangement of another surgical tool embodiment of the present invention;

[0065]FIG. 49B is a cross-sectional perspective view of the gear
arrangement shown in FIG. 49A;

[0066]FIG. 50 is a cross-sectional side view of a portion of a surgical
end effector and elongated shaft assembly of another surgical tool
embodiment of the present invention employing a pressure sensor
arrangement with the anvil in the open position;

[0067]FIG. 51 is another cross-sectional side view of a portion of the
surgical end effector and elongated shaft assembly of the surgical tool
embodiment of FIG. 50 with the anvil in the closed position;

[0068] FIG. 52 is a side view of a portion of another surgical tool
embodiment of the present invention in relation to a tool holder portion
of a robotic system with some of the components thereof shown in
cross-section;

[0069] FIG. 53 is a side view of a portion of another surgical tool
embodiment of the present invention in relation to a tool holder portion
of a robotic system with some of the components thereof shown in
cross-section;

[0070]FIG. 54 is a side view of a portion of another surgical tool
embodiment of the present invention with some of the components thereof
shown in cross-section;

[0071]FIG. 55 is a side view of a portion of another surgical end
effector embodiment of a portion of a surgical tool embodiment of the
present invention with some components thereof shown in cross-section;

[0072]FIG. 56 is a side view of a portion of another surgical end
effector embodiment of a portion of a surgical tool embodiment of the
present invention with some components thereof shown in cross-section;

[0073]FIG. 57 is a side view of a portion of another surgical end
effector embodiment of a portion of a surgical tool embodiment of the
present invention with some components thereof shown in cross-section;

[0074]FIG. 58 is an enlarged cross-sectional view of a portion of the end
effector of FIG. 57;

[0075]FIG. 59 is another cross-sectional view of a portion of the end
effector of FIGS. 57 and 58;

[0076]FIG. 60 is a cross-sectional side view of a portion of a surgical
end effector and elongated shaft assembly of another surgical tool
embodiment of the present invention with the anvil in the open position;

[0077]FIG. 61 is an enlarged cross-sectional side view of a portion of
the surgical end effector and elongated shaft assembly of the surgical
tool embodiment of FIG. 60;

[0078]FIG. 62 is another cross-sectional side view of a portion of the
surgical end effector and elongated shaft assembly of FIGS. 60 and 61
with the anvil thereof in the closed position;

[0079] FIG. 63 is an enlarged cross-sectional side view of a portion of
the surgical end effector and elongated shaft assembly of the surgical
tool embodiment of FIGS. 60-62;

[0080]FIG. 64 is a top view of a tool mounting portion embodiment of a
surgical tool embodiment of the present invention;

[0081]FIG. 65 is a perspective assembly view of another surgical tool
embodiment of the present invention;

[0082]FIG. 66 is a front perspective view of a disposable loading unit
arrangement that may be employed with various surgical tool embodiments
of the present invention;

[0083] FIG. 67 is a rear perspective view of the disposable loading unit
of FIG. 66;

[0084]FIG. 68 is a bottom perspective view of the disposable loading unit
of FIGS. 66 and 67;

[0085]FIG. 69 is a bottom perspective view of another disposable loading
unit embodiment that may be employed with various surgical tool
embodiments of the present invention;

[0086]FIG. 70 is an exploded perspective view of a mounting portion of a
disposable loading unit depicted in FIGS. 66-68;

[0087]FIG. 71 is a perspective view of a portion of a disposable loading
unit and an elongated shaft assembly embodiment of a surgical tool
embodiment of the present invention with the disposable loading unit in a
first position;

[0088]FIG. 72 is another perspective view of a portion of the disposable
loading unit and elongated shaft assembly of FIG. 71 with the disposable
loading unit in a second position;

[0089] FIG. 73 is a cross-sectional view of a portion of the disposable
loading unit and elongated shaft assembly embodiment depicted in FIGS. 71
and 72;

[0090]FIG. 74 is another cross-sectional view of the disposable loading
unit and elongated shaft assembly embodiment depicted in FIGS. 71-73;

[0091]FIG. 75 is a partial exploded perspective view of a portion of
another disposable loading unit embodiment and an elongated shaft
assembly embodiment of a surgical tool embodiment of the present
invention;

[0092]FIG. 76 is a partial exploded perspective view of a portion of
another disposable loading unit embodiment and an elongated shaft
assembly embodiment of a surgical tool embodiment of the present
invention;

[0093]FIG. 77 is another partial exploded perspective view of the
disposable loading unit embodiment and an elongated shaft assembly
embodiment of FIG. 76;

[0094]FIG. 78 is a top view of another tool mounting portion embodiment
of a surgical tool embodiment of the present invention;

[0095]FIG. 79 is a side view of another surgical tool embodiment of the
present invention with some of the components thereof shown in
cross-section and in relation to a robotic tool holder of a robotic
system;

[0096]FIG. 80 is an exploded assembly view of a surgical end effector
embodiment that may be used in connection with various surgical tool
embodiments of the present invention;

[0097] FIG. 81 is a side view of a portion of a cable-driven system for
driving a cutting instrument employed in various surgical end effector
embodiments of the present invention;

[0098] FIG. 82 is a top view of the cable-driven system and cutting
instrument of FIG. 81;

[0099] FIG. 83 is a top view of a cable drive transmission embodiment of
the present invention in a closure position;

[0100]FIG. 84 is another top view of the cable drive transmission
embodiment of FIG. 83 in a neutral position;

[0101]FIG. 85 is another top view of the cable drive transmission
embodiment of FIGS. 83 and 84 in a firing position;

[0102] FIG. 86 is a perspective view of the cable drive transmission
embodiment in the position depicted in FIG. 83;

[0103] FIG. 87 is a perspective view of the cable drive transmission
embodiment in the position depicted in FIG. 84;

[0104] FIG. 88 is a perspective view of the cable drive transmission
embodiment in the position depicted in FIG. 85;

[0105]FIG. 89 is a perspective view of another surgical tool embodiment
of the present invention;

[0106]FIG. 90 is a side view of a portion of another cable-driven system
embodiment for driving a cutting instrument employed in various surgical
end effector embodiments of the present invention;

[0107]FIG. 91 is a top view of the cable-driven system embodiment of FIG.
90;

[0108]FIG. 92 is a top view of a tool mounting portion embodiment of
another surgical tool embodiment of the present invention;

[0109] FIG. 93 is a top cross-sectional view of another surgical tool
embodiment of the present invention;

[0110]FIG. 94 is a cross-sectional view of a portion of a surgical end
effector embodiment of a surgical tool embodiment of the present
invention;

[0111] FIG. 95 is a cross-sectional end view of the surgical end effector
of FIG. 103 taken along line 95-95 in FIG. 94;

[0112]FIG. 96 is a perspective view of the surgical end effector of FIGS.
94 and 95 with portions thereof shown in cross-section;

[0113] FIG. 97 is a side view of a portion of the surgical end effector of
FIGS. 94-96;

[0114]FIG. 98 is a perspective view of a sled assembly embodiment of
various surgical tool embodiments of the present invention;

[0115]FIG. 99 is a cross-sectional view of the sled assembly embodiment
of FIG. 98 and a portion of the elongated channel of FIG. 97;

[0116] FIGS. 100-105 diagrammatically depict the sequential firing of
staples in a surgical tool embodiment of the present invention;

[0117] FIG. 106 is a partial perspective view of a portion of a surgical
end effector embodiment of the present invention;

[0118] FIG. 107 is a partial cross-sectional perspective view of a portion
of a surgical end effector embodiment of a surgical tool embodiment of
the present invention;

[0119] FIG. 108 is another partial cross-sectional perspective view of the
surgical end effector embodiment of FIG. 107 with a sled assembly axially
advancing therethrough;

[0120] FIG. 109 is a perspective view of another sled assembly embodiment
of another surgical tool embodiment of the present invention;

[0121] FIG. 110 is a partial top view of a portion of the surgical end
effector embodiment depicted in FIGS. 107 and 108 with the sled assembly
axially advancing therethrough;

[0122] FIG. 111 is another partial top view of the surgical end effector
embodiment of FIG. 110 with the top surface of the surgical staple
cartridge omitted for clarity;

[0123] FIG. 112 is a partial cross-sectional side view of a rotary driver
embodiment and staple pusher embodiment of the surgical end effector
depicted in FIGS. 107 and 108;

[0124] FIG. 113 is a perspective view of an automated reloading system
embodiment of the present invention with a surgical end effector in
extractive engagement with the extraction system thereof;

[0125] FIG. 114 is another perspective view of the automated reloading
system embodiment depicted in FIG. 113;

[0126] FIG. 115 is a cross-sectional elevational view of the automated
reloading system embodiment depicted in FIGS. 113 and 114;

[0127] FIG. 116 is another cross-sectional elevational view of the
automated reloading system embodiment depicted in FIGS. 113-115 with the
extraction system thereof removing a spent surgical staple cartridge from
the surgical end effector;

[0128] FIG. 117 is another cross-sectional elevational view of the
automated reloading system embodiment depicted in FIGS. 113-116
illustrating the loading of a new surgical staple cartridge into a
surgical end effector;

[0129] FIG. 118 is a perspective view of another automated reloading
system embodiment of the present invention with some components shown in
cross-section;

[0130] FIG. 119 is an exploded perspective view of a portion of the
automated reloading system embodiment of FIG. 118;

[0131] FIG. 120 is another exploded perspective view of the portion of the
automated reloading system embodiment depicted in FIG. 119;

[0132] FIG. 121 is a cross-sectional elevational view of the automated
reloading system embodiment of FIGS. 118-120;

[0134] FIG. 123 is a perspective view of another surgical tool embodiment
of the present invention;

[0135] FIG. 124 is a partial perspective view of an articulation joint
embodiment of a surgical tool embodiment of the present invention;

[0136] FIG. 125 is a perspective view of a closure tube embodiment of a
surgical tool embodiment of the present invention;

[0137] FIG. 126 is a perspective view of the closure tube embodiment of
FIG. 125 assembled on the articulation joint embodiment of FIG. 124;

[0138] FIG. 127 is a top view of a portion of a tool mounting portion
embodiment of a surgical tool embodiment of the present invention;

[0139] FIG. 128 is a perspective view of an articulation drive assembly
embodiment employed in the tool mounting portion embodiment of FIG. 127;

[0140] FIG. 129 is a perspective view of another surgical tool embodiment
of the present invention; and

[0141] FIG. 130 is a perspective view of another surgical tool embodiment
of the present invention.

DETAILED DESCRIPTION

[0142] Applicant of the present application also owns the following patent
applications that have been filed on even date herewith and which are
each herein incorporated by reference in their respective entireties:

[0143] U.S. patent application Ser. No. ______, entitled "Surgical
Instrument With Wireless Communication Between a Control Unit of a
Robotic System and Remote Sensor", Attorney Docket No.
END5924USCIP2/060339CIP2;

[0153] Certain exemplary embodiments will now be described to provide an
overall understanding of the principles of the structure, function,
manufacture, and use of the devices and methods disclosed herein. One or
more examples of these embodiments are illustrated in the accompanying
drawings. Those of ordinary skill in the art will understand that the
devices and methods specifically described herein and illustrated in the
accompanying drawings are non-limiting exemplary embodiments and that the
scope of the various embodiments of the present invention is defined
solely by the claims. The features illustrated or described in connection
with one exemplary embodiment may be combined with the features of other
embodiments. Such modifications and variations are intended to be
included within the scope of the present invention.

[0154] Uses of the phrases "in various embodiments," "in some
embodiments," "in one embodiment", or "in an embodiment", or the like,
throughout the specification are not necessarily all referring to the
same embodiment. Furthermore, the particular features, structures, or
characteristics of one or more embodiments may be combined in any
suitable manner in one or more other embodiments. Such modifications and
variations are intended to be included within the scope of the present
invention.

[0155] Turning to the Drawings, wherein like numerals denote like
components throughout the several views, FIG. 1 depicts a disposable
loading unit 16 of the present invention that is coupled to a
conventional surgical cutting and stapling apparatus 10. The construction
and general operation of a cutting and stapling apparatus 10 is described
in U.S. Pat. No. 5,865,361, the disclosure of which has been herein
incorporated by reference. Thus, the present Detailed Description will
not discuss the various components of the apparatus 10 and their
operation herein beyond what is necessary to describe the operation of
the disposable loading unit 16 of the present invention.

[0156] As the present Detailed Description proceeds, it will be
appreciated that the terms "proximal" and "distal" are used herein with
reference to a clinician gripping a handle assembly 12 of the surgical
stapling apparatus 10 to which the disposable loading unit 16 is
attached. Thus, the disposable loading unit 16 is distal with respect to
the more proximal handle assembly 12. It will be further appreciated
that, for convenience and clarity, spatial terms such as "vertical",
"horizontal", "up", "down", "right", and "left" are used herein with
respect to the drawings. However, surgical instruments are used in many
orientations and positions, and these terms are not intended to be
limiting and absolute.

[0157] As can be seen in FIG. 1, the disposable loading unit 16 may
generally comprise a tool assembly 17 for performing surgical procedures
such as cutting tissue and applying staples on each side of the cut. The
tool assembly 17 may include a cartridge assembly 18 that includes a
staple cartridge 220 that is supported in a carrier 216. An anvil
assembly 20 may be pivotally coupled to the carrier 216 in a known manner
for selective pivotal travel between open and closed positions. The anvil
assembly 20 includes an anvil portion 204 that has a plurality of staple
deforming concavities (not shown) formed in the undersurface thereof. The
staple cartridge 220 houses a plurality of pushers or drivers (not shown)
that each have a staple or staples (not shown) supported thereon. An
actuation sled 234 is supported within the tool assembly 17 and is
configured to drive the pushers and staples in the staple cartridge 220
in a direction toward the anvil assembly 20 as the actuation sled 234 is
driven from the proximal end of the tool assembly 17 to the distal end
220. See FIG. 2.

[0158] The disposable loading unit 16 may further include an axial drive
assembly 212 that comprises a drive beam 266 that may be constructed from
a single sheet of material or, preferably, from multiple stacked sheets.
However, the drive beam 266 may be constructed from other suitable
material configurations. The distal end of drive beam 266 may include a
vertical support strut 271 which supports a knife blade 280 and an
abutment surface 283 which engages the central portion of actuation sled
234 during a stapling procedure. Knife blade 280 may be generally
positioned to translate slightly behind actuation sled 234 through a
central longitudinal slot in staple cartridge 220 to form an incision
between rows of stapled body tissue. A retention flange 284 may project
distally from vertical strut 271 and support a camming pin or pins 286 at
its distal end. Camming pin 286 may be dimensioned and configured to
engage camming surface 209 on anvil portion 204 to clamp anvil portion
204 against body tissue. See FIGS. 5 and 7. In addition, a leaf spring
(not shown) may be provided between the proximal end of the anvil portion
204 and the distal end portion of the housing 200 to bias the anvil
assembly 20 to a normally open position. The carrier 216 may also have an
elongated bottom slot therethrough through which a portion of the
vertical support strut 271 extends to have a support member 287 attached
thereto

[0159] As can also be seen in FIG. 1, the disposable loading unit 16 may
also have a housing portion 200 that is adapted to snap onto or otherwise
be attached to the carrier 216. The proximal end 500 of housing 200 may
include engagement nubs 254 for releasably engaging elongated body 14 of
a surgical stapling apparatus. Nubs 254 form a bayonet type coupling with
the distal end of the elongated body portion 14 of the surgical stapling
apparatus as described in U.S. Pat. No. 5,865,361.

[0160] The housing 200 may further include a switch portion 520 that
movably houses a battery 526 therein. More specifically and with
reference to FIG. 3, the switch portion 520 of the housing 200 defines a
battery cavity 522 that movably supports a battery holder 524 that houses
a battery 526 therein. As can be seen in FIG. 3, a first battery contact
528 is supported in electrical contact with the battery 526 and protrudes
out through the battery holder 524 for sliding engagement with the inside
wall 523 of the battery cavity 522. Similarly, a second battery contact
530 is mounted in electrical contact with the battery 526 and also
protrudes out of the battery holder 524 to slide along the inside wall
523 of the battery cavity 522. The battery holder 524 has a control rod
socket 532 therein configured to receive the distal end 276 of control
rod 52 when the proximal end of disposable loading unit 16 is coupled to
the elongated body 14 of surgical stapling apparatus 10. As can also be
seen in FIG. 3, a series of contacts 540, 542, 544 may be oriented within
the wall 523 for contact with the battery contacts 530. The purpose of
the contacts 540, 542, and 544 will be discussed in further detail below.
As can also be seen in FIG. 3, a biasing member or switch spring 550 is
positioned within the battery cavity 522 to bias the battery holder 524
in the proximal direction "PD" such that when the disposable reload 16 is
not attached to the elongated body 14, the battery holder 524 is biased
to its proximal-most position shown in FIG. 3. When retained in that
"pre-use" or "disconnected" position by spring 550, the battery contacts
528 and 530 do not contact any of the contacts 540, 542, 544 within the
battery cavity 522 to prevent the battery 526 from being drained during
non-use.

[0161] As can also be seen in FIG. 3, the housing 200 may further have a
motor cavity 560 therein that houses a motor 562 and a gear box 564. The
gear box 564 has an output shaft 566 that protrudes through a hole 572 in
a proximal bulkhead 570 formed in the housing 200. See FIG. 5. The output
shaft 566 is keyed onto or otherwise non-rotatably coupled to a thrust
disc 580. As can be seen in FIG. 5, the thrust disc 580 is rotatably
supported within a thrust disc cavity 582 formed between the proximal
bulkhead 570 and a distal bulkhead 590 formed in the housing 200. In
addition, the thrust disc 580 is rotatably supported between a proximal
thrust bearing 583 and a distal thrust bearing 584 as shown. As can also
be seen in FIG. 5, the thrust disc 580 may be formed on a proximal end of
a drive screw 600 that threadedly engages a drive nut 610 that is
supported within an engagement section 270 formed on the distal end of
the drive beam 266. In various embodiments, the engagement section 270
may include a pair of engagement fingers 270a and 270b that are
dimensioned and configured to be received within a slot in the drive nut
610 to non-rotatably affix the drive nut 610 to the drive beam 266. Thus,
rotation of the drive screw 600 within the drive nut 610 will drive the
drive beam 266 in the distal direction "DD" or in the proximal direction
"PD" depending upon the direction of rotation of the drive screw 600.

[0162] The disposable loading unit 16 may further include a return switch
630 that is mounted in the housing 200 and is adapted to be actuated by
the knife nut 610. As can also be seen in FIG. 5, a switch 640 is mounted
in the housing 200 and is also oriented to be actuated by the knife nut
610 to indicate when the anvil assembly 20 has been closed. A switch 650
is mounted in the housing 200 and is also adapted to be actuated by the
knife nut 610 to indicate that the axial drive assembly 212 has moved to
is finished position. The specific operations of switches 630, 640, 650
will be discussed in further detail below.

[0163]FIG. 4 illustrates a circuit embodiment 700 of the present
invention that illustrates the positions of various components of the
disposable loading unit 16 of the present invention when in a "pre-use"
condition. For example, the various components of the disposable loading
unit 16 may be in this pre-use orientation when the unit 16 is being
stored or shipped. As can be seen in that Figure, when in this
orientation, the battery contacts 528 and 530 do not contact any of the
contacts 540, 542, 544 in the housing 200 which prevents the battery 526
from being drained during non-use.

[0164] FIGS. 5 and 6 illustrate the positions of various components of the
disposable loading unit 16 after it has been coupled to the elongated
body 14 of the surgical cutting and stapling instrument 10. In
particular, as can be seen in FIG. 5, the distal end 276 of the control
rod 52 has been coupled to the battery holder 524. When the control rod
52 is attached to the battery holder 524, the battery holder 524 is moved
in the distal direction "DD" against the spring 550 such that the battery
contacts 528, 530 are brought into contact with the return contacts 540
in the housing 200. Also, when in that position, the knife nut 610
actuates the return switch 630 into an open orientation. It will be
appreciated that the return switch 630 is a normally closed switch that
is actuated to the open position by the knife nut 610. As shown in FIG.
6, when the return switch 630 is open, the motor 562 is not powered.

[0165] FIGS. 7 and 8 illustrate the positions of various components of the
disposable loading unit 16 after the clinician has actuated the movable
handle 24 (shown in FIG. 1) of the surgical cutting and stapling
instrument 10. As discussed in U.S. Pat. No. 5,865,361, when the movable
handle 24 is initially moved toward the stationary handle member 22, the
control rod 52 is caused to move in the distal direction "DD". As can be
seen in FIG. 7, as the control rod 52 is initially moved in the distal
direction during the anvil close stroke, the battery holder 524 moves the
battery 526 to a position wherein the battery contacts 528, 530 contact
the anvil close contacts 542. Power is now permitted to flow from the
battery 526 to the motor 562 which rotates the drive screw 600 and causes
the drive beam 266 to move distally. As the drive beam 266 moves distally
in the "DD" direction, the camming pin 286 engages cam portion 209 of
anvil portion 204 and causes the anvil assembly 20 to pivot to a closed
position as illustrated in FIG. 7. As the drive beam 266 moves distally
to the anvil closed position, the knife nut 610 moves out of contact with
the return switch 630 which permits the return switch to resume its
normally open position. The knife nut 610 then actuates the anvil closed
switch 640 and moves it to an open position. See FIG. 8. In various
embodiments one or more anvil closed lights 660 may be mounted in the
housing 200 for providing a visual indication to the clinician that the
anvil assembly 20 has been moved to the closed position.

[0166] When the clinician desires to fire the instrument 10 (i.e., actuate
the instrument 10 to cause it to cut and staple tissue), the clinician
first depresses the plunger 82 of the firing lockout assembly 80 (FIG. 1)
as discussed in U.S. Pat. No. 5,865,361. Thereafter, movable handle 24
may be actuated. As the movable handle 24 is depressed, the control rod
52 moves the battery holder 524 and battery 526 to the position
illustrated in FIGS. 9 and 10. As can be seen in those Figures, when the
battery 526 is moved into that position, the battery contacts 528, 530
are brought into contact with the fire contacts 544. The switch 650 is
normally closed until it is actuated by the knife nut 610. Thus, when the
battery contacts 528, 530 contact the firing contacts 544, power flows
from the battery 526 to the motor 562 which drives the drive screw 600.
As the drive screw 600 is rotated, the drive beam 266 and knife nut 610
are driven in the distal direction "DD" to advance actuation sled 234
through staple cartridge 220 to effect ejection of staples and cutting of
tissue. Once the drive beam 266 reaches the end of the firing stroke
(i.e., all of the staples in the staple cartridge 220 have been fired),
knife nut 610 is positioned to actuate the normally closed switch 650 and
move it to an open position (illustrated in FIG. 10) which stops the flow
of power from the battery 526 to the motor 562. In various embodiments, a
distal indication light or lights 670 may be mounted on the housing 200
to provide an indication to the clinician that the drive beam 266 has
reached its distal-most fired position.

[0167] To retract the drive beam 266, the clinician grasps the retract
knobs 32 (shown in FIG. 1) on the handle assembly 12 and pulls them in
the proximal direction "PD". The operation and construction of the
retract knobs 32 is discussed in U.S. Pat. No. 5,865,361. Once the
clinician moves the drive beam 266 a sufficient distance in the proximal
direction "PD" so as to move the battery to contacts 540 (FIG. 11), power
will be supplied through switch 630 to reverse the motor 562. Knife nut
then releases switch 650. The motor 562 then drives the drive beam 266
distal to switch 630, which opens. The return switch 630 is also in its
normally closed position thereby permitting power to flow to the motor
562 and rotate the drive screw 610 in an opposite direction to drive the
drive beam 266 in the proximal direction "PD". Once the knife nut 610
actuates the knife return switch 630, the knife return switch 630 is
moved to an open position thereby stopping flow of power from the battery
526 to the motor 562. In various embodiments, a starting light 700 may be
mounted in the housing 200 to provide an indication that the drive beam
266 is in the starting position.

[0168] FIGS. 11 and 12 illustrate the positions of various components of
the disposable loading unit 16 of the present invention when the distal
end of the drive beam 266 and blade 280 inadvertently becomes jammed
during the firing stroke (i.e., when the blade 280 is being distally
advanced through the tissue clamped in the tool assembly 17). To address
such occurrence, a current limiter 680 may be provided as shown in FIG.
12. The current limiter 680 serves to turn off the motor 562 when the
amount of current that it is drawing exceeds a predetermined threshold.
It will be understood that the amount of current that the motor 562 draws
during a jam would increase over the amount of current drawn during
normal firing operations. Once the current limiter 680 shuts down the
motor 562, the clinician can retract the drive beam 266 by grasping the
retract knobs 32 (shown in FIG. 1) on the handle assembly 12 and pulling
them in the proximal direction "PD" and the motor 562 will drive the
drive screw 600 in reverse in the manner described above. Thus, the
current limiter 680 serves to stop the motor 562 when the axial drive
assembly 212 encounters resistance that exceeds a predetermined amount of
resistance which is associated with the predetermined maximum amount of
current that the motor 562 should draw under normal operating
circumstances. This feature also saves the battery power so the drive
beam 266 can be retracted.

[0169] Thus, the disposable loading unit 16 of the present invention
comprises a self-contained motor driven disposable loading unit that may
be used in connection with conventional surgical cutting and stapling
instruments that traditionally required the clinician to manually advance
and retract the drive assembly and cutting blade of a disposable loading
unit coupled thereto. Various embodiments of the disposable loading unit
16 may be constructed to facilitate the automatic retraction of the axial
drive assembly should the blade encounter a predetermined amount of
resistance.

[0170] While several embodiments of the invention have been described, it
should be apparent, however, that various modifications, alterations and
adaptations to those embodiments may occur to persons skilled in the art
with the attainment of some or all of the advantages of the invention.
For example, according to various embodiments, a single component may be
replaced by multiple components, and multiple components may be replaced
by a single component, to perform a given function or functions. This
application is therefore intended to cover all such modifications,
alterations and adaptations without departing from the scope and spirit
of the disclosed invention as defined by the appended claims.

[0171] Any patent, publication, or other disclosure material, in whole or
in part, that is said to be incorporated by reference herein is
incorporated herein only to the extent that the incorporated materials
does not conflict with existing definitions, statements, or other
disclosure material set forth in this disclosure. As such, and to the
extent necessary, the disclosure as explicitly set forth herein
supersedes any conflicting material incorporated herein by reference. Any
material, or portion thereof, that is said to be incorporated by
reference herein, but which conflicts with existing definitions,
statements, or other disclosure material set forth herein will only be
incorporated to the extent that no conflict arises between that
incorporated material and the existing disclosure material.

[0172] The invention which is intended to be protected is not to be
construed as limited to the particular embodiments disclosed. The
embodiments are therefore to be regarded as illustrative rather than
restrictive. Variations and changes may be made by others without
departing from the spirit of the present invention. Accordingly, it is
expressly intended that all such equivalents, variations and changes
which fall within the spirit and scope of the present invention as
defined in the claims be embraced thereby.

[0173] Over the years a variety of minimally invasive robotic (or
"telesurgical") systems have been developed to increase surgical
dexterity as well as to permit a surgeon to operate on a patient in an
intuitive manner. Many of such systems are disclosed in the following
U.S. patents which are each herein incorporated by reference in their
respective entirety: U.S. Pat. No. 5,792,135, entitled "Articulated
Surgical Instrument For Performing Minimally Invasive Surgery With
Enhanced Dexterity and Sensitivity", U.S. Pat. No. 6,231,565, entitled
"Robotic Arm DLUS For Performing Surgical Tasks", U.S. Pat. No.
6,783,524, entitled "Robotic Surgical Tool With Ultrasound Cauterizing
and Cutting Instrument", U.S. Pat. No. 6,364,888, entitled "Alignment of
Master and Slave In a Minimally Invasive Surgical Apparatus", U.S. Pat.
No. 7,524,320, entitled "Mechanical Actuator Interface System For Robotic
Surgical Tools", U.S. Pat. No. 7,691,098, entitled Platform Link Wrist
Mechanism", U.S. Pat. No. 7,806,891, entitled "Repositioning and
Reorientation of Master/Slave Relationship in Minimally Invasive
Telesurgery", and U.S. Pat. No. 7,824,401, entitled "Surgical Tool With
Writed Monopolar Electrosurgical End Effectors". Many of such systems,
however, have in the past been unable to generate the magnitude of forces
required to effectively cut and fasten tissue.

[0174] FIG. 13 depicts one version of a master controller 1001 that may be
used in connection with a robotic arm slave cart 1100 of the type
depicted in FIG. 14. Master controller 1001 and robotic arm slave cart
1100, as well as their respective components and control systems are
collectively referred to herein as a robotic system 1000. Examples of
such systems and devices are disclosed in U.S. Pat. No. 7,524,320 which
has been herein incorporated by reference. Thus, various details of such
devices will not be described in detail herein beyond that which may be
necessary to understand various embodiments and forms of the present
invention. As is known, the master controller 1001 generally includes
master controllers (generally represented as 1003 in FIG. 13) which are
grasped by the surgeon and manipulated in space while the surgeon views
the procedure via a stereo display 1002. The master controllers 1001
generally comprise manual input devices which preferably move with
multiple degrees of freedom, and which often further have an actuatable
handle for actuating tools (for example, for closing grasping saws,
applying an electrical potential to an electrode, or the like).

[0175] As can be seen in FIG. 14, in one form, the robotic arm cart 1100
is configured to actuate a plurality of surgical tools, generally
designated as 1200. Various robotic surgery systems and methods employing
master controller and robotic arm cart arrangements are disclosed in U.S.
Pat. No. 6,132,368, entitled "Multi-Component Telepresence System and
Method", the full disclosure of which is incorporated herein by
reference. In various forms, the robotic arm cart 1100 includes a base
1002 from which, in the illustrated embodiment, three surgical tools 1200
are supported. In various forms, the surgical tools 1200 are each
supported by a series of manually articulatable linkages, generally
referred to as set-up joints 1104, and a robotic manipulator 1106. These
structures are herein illustrated with protective covers extending over
much of the robotic linkage. These protective covers may be optional, and
may be limited in size or entirely eliminated in some embodiments to
minimize the inertia that is encountered by the servo mechanisms used to
manipulate such devices, to limit the volume of moving components so as
to avoid collisions, and to limit the overall weight of the cart 1100.
Cart 1100 will generally have dimensions suitable for transporting the
cart 1100 between operating rooms. The cart 1100 may be configured to
typically fit through standard operating room doors and onto standard
hospital elevators. In various forms, the cart 1100 would preferably have
a weight and include a wheel (or other transportation) system that allows
the cart 1100 to be positioned adjacent an operating table by a single
attendant.

[0176] Referring now to FIG. 15, in at least one form, robotic
manipulators 1106 may include a linkage 1108 that constrains movement of
the surgical tool 1200. In various embodiments, linkage 1108 includes
rigid links coupled together by rotational joints in a parallelogram
arrangement so that the surgical tool 1200 rotates around a point in
space 1110, as more fully described in issued U.S. Pat. No. 5,817,084,
the full disclosure of which is herein incorporated by reference. The
parallelogram arrangement constrains rotation to pivoting about an axis
1112a, sometimes called the pitch axis. The links supporting the
parallelogram linkage are pivotally mounted to set-up joints 1104 (FIG.
14) so that the surgical tool 1200 further rotates about an axis 1112b,
sometimes called the yaw axis. The pitch and yaw axes 1112a, 1112b
intersect at the remote center 1114, which is aligned along a shaft 1208
of the surgical tool 1200. The surgical tool 1200 may have further
degrees of driven freedom as supported by manipulator 1106, including
sliding motion of the surgical tool 1200 along the longitudinal tool axis
"LT-LT". As the surgical tool 1200 slides along the tool axis LT-LT
relative to manipulator 1106 (arrow 1112c), remote center 1114 remains
fixed relative to base 1116 of manipulator 1106. Hence, the entire
manipulator is generally moved to re-position remote center 1114. Linkage
1108 of manipulator 1106 is driven by a series of motors 1120. These
motors actively move linkage 1108 in response to commands from a
processor of a control system. As will be discussed in further detail
below, motors 1120 are also employed to manipulate the surgical tool
1200.

[0177] An alternative set-up joint structure is illustrated in FIG. 16. In
this embodiment, a surgical tool 1200 is supported by an alternative
manipulator structure 1106' between two tissue manipulation tools. Those
of ordinary skill in the art will appreciate that various embodiments of
the present invention may incorporate a wide variety of alternative
robotic structures, including those described in U.S. Pat. No. 5,878,193,
entitled "Automated Endoscope System For Optimal Positioning", the full
disclosure of which is incorporated herein by reference. Additionally,
while the data communication between a robotic component and the
processor of the robotic surgical system is primarily described herein
with reference to communication between the surgical tool 1200 and the
master controller 1001, it should be understood that similar
communication may take place between circuitry of a manipulator, a set-up
joint, an endoscope or other image capture device, or the like, and the
processor of the robotic surgical system for component compatibility
verification, component-type identification, component calibration (such
as off-set or the like) communication, confirmation of coupling of the
component to the robotic surgical system, or the like.

[0178] An exemplary non-limiting surgical tool 1200 that is well-adapted
for use with a robotic system 1000 that has a tool drive assembly 1010
(FIG. 18) that is operatively coupled to a master controller 1001 that is
operable by inputs from an operator (i.e., a surgeon) is depicted in FIG.
17. As can be seen in that Figure, the surgical tool 1200 includes a
surgical end effector 2012 that comprises an endocutter. In at least one
form, the surgical tool 1200 generally includes an elongated shaft
assembly 2008 that has a proximal closure tube 2040 and a distal closure
tube 2042 that are coupled together by an articulation joint 2011. The
surgical tool 1200 is operably coupled to the manipulator by a tool
mounting portion, generally designated as 1300. The surgical tool 1200
further includes an interface 1230 which mechanically and electrically
couples the tool mounting portion 1300 to the manipulator. One form of
interface 1230 is illustrated in FIGS. 16-22. In various embodiments, the
tool mounting portion 1300 includes a tool mounting plate 1302 that
operably supports a plurality of (four are shown in FIG. 22) rotatable
body portions, driven discs or elements 1304, that each include a pair of
pins 1306 that extend from a surface of the driven element 1304. One pin
1306 is closer to an axis of rotation of each driven elements 1304 than
the other pin 1306 on the same driven element 1304, which helps to ensure
positive angular alignment of the driven element 1304. Interface 1230
includes an adaptor portion 1240 that is configured to mountingly engage
the mounting plate 1302 as will be further discussed below. The adaptor
portion 1240 may include an array of electrical connecting pins 1242
(FIG. 20) which may be coupled to a memory structure by a circuit board
within the tool mounting portion 1300. While interface 1230 is described
herein with reference to mechanical, electrical, and magnetic coupling
elements, it should be understood that a wide variety of telemetry
modalities might be used, including infrared, inductive coupling, or the
like.

[0179] As can be seen in FIGS. 18-21, the adapter portion 1240 generally
includes a tool side 1244 and a holder side 1246. In various forms, a
plurality of rotatable bodies 1250 are mounted to a floating plate 1248
which has a limited range of movement relative to the surrounding adaptor
structure normal to the major surfaces of the adaptor 1240. Axial
movement of the floating plate 1248 helps decouple the rotatable bodies
1250 from the tool mounting portion 1300 when the levers 1303 along the
sides of the tool mounting portion housing 1301 are actuated (See FIG.
17). Other mechanisms/arrangements may be employed for releasably
coupling the tool mounting portion 1300 to the adaptor 1240. In at least
one form, rotatable bodies 1250 are resiliently mounted to floating plate
1248 by resilient radial members which extend into a circumferential
indentation about the rotatable bodies 1250. The rotatable bodies 1250
can move axially relative to plate 1248 by deflection of these resilient
structures. When disposed in a first axial position (toward tool side
1244) the rotatable bodies 1250 are free to rotate without angular
limitation. However, as the rotatable bodies 1250 move axially toward
tool side 1244, tabs 1252 (extending radially from the rotatable bodies
1250) laterally engage detents on the floating plates so as to limit
angular rotation of the rotatable bodies 1250 about their axes. This
limited rotation can be used to help drivingly engage the rotatable
bodies 1250 with drive pins 1272 of a corresponding tool holder portion
1270 of the robotic system 1000, as the drive pins 1272 will push the
rotatable bodies 1250 into the limited rotation position until the pins
1234 are aligned with (and slide into) openings 1256'. Openings 1256 on
the tool side 1244 and openings 1256' on the holder side 1246 of
rotatable bodies 1250 are configured to accurately align the driven
elements 1304 (FIG. 22) of the tool mounting portion 1300 with the drive
elements 1271 of the tool holder 1270. As described above regarding inner
and outer pins 1306 of driven elements 1304, the openings 1256, 1256' are
at differing distances from the axis of rotation on their respective
rotatable bodies 1250 so as to ensure that the alignment is not 180
degrees from its intended position. Additionally, each of the openings
1256 is slightly radially elongated so as to fittingly receive the pins
1306 in the circumferential orientation. This allows the pins 1306 to
slide radially within the openings 1256, 1256' and accommodate some axial
misalignment between the tool 1200 and tool holder 1270, while minimizing
any angular misalignment and backlash between the drive and driven
elements. Openings 1256 on the tool side 1244 are offset by about 90
degrees from the openings 1256' (shown in broken lines) on the holder
side 1246, as can be seen most clearly in FIG. 21.

[0180] Various embodiments may further include an array of electrical
connector pins 1242 located on holder side 1246 of adaptor 1240, and the
tool side 1244 of the adaptor 1240 may include slots 1258 (FIG. 21) for
receiving a pin array (not shown) from the tool mounting portion 1300. In
addition to transmitting electrical signals between the surgical tool
1200 and the tool holder 1270, at least some of these electrical
connections may be coupled to an adaptor memory device 1260 (FIG. 20) by
a circuit board of the adaptor 1240.

[0181] A detachable latch arrangement 1239 may be employed to releasably
affix the adaptor 1240 to the tool holder 1270. As used herein, the term
"tool drive assembly" when used in the context of the robotic system
1000, at least encompasses various embodiments of the adapter 1240 and
tool holder 1270 and which has been generally designated as 1010 in FIG.
18. For example, as can be seen in FIG. 18, the tool holder 1270 may
include a first latch pin arrangement 1274 that is sized to be received
in corresponding clevis slots 1241 provided in the adaptor 1240. In
addition, the tool holder 1270 may further have second latch pins 1276
that are sized to be retained in corresponding latch devises 1243 in the
adaptor 1240. See FIG. 20. In at least one form, a latch assembly 1245 is
movably supported on the adapter 1240 and is biasable between a first
latched position wherein the latch pins 1276 are retained within their
respective latch clevis 1243 and an unlatched position wherein the second
latch pins 1276 may be into or removed from the latch devises 1243. A
spring or springs (not shown) are employed to bias the latch assembly
into the latched position. A lip on the tool side 1244 of adaptor 1240
may slidably receive laterally extending tabs of tool mounting housing
1301.

[0182] Turning next to FIGS. 22-29, in at least one embodiment, the
surgical tool 1200 includes a surgical end effector 2012 that comprises
in this example, among other things, at least one component 2024 that is
selectively movable between first and second positions relative to at
least one other component 2022 in response to various control motions
applied thereto as will be discussed in further detail below. In various
embodiments, component 2022 comprises an elongated channel 2022
configured to operably support a surgical staple cartridge 2034 therein
and component 2024 comprises a pivotally translatable clamping member,
such as an anvil 2024. Various embodiments of the surgical end effector
2012 are configured to maintain the anvil 2024 and elongated channel 2022
at a spacing that assures effective stapling and severing of tissue
clamped in the surgical end effector 2012. As can be seen in FIG. 28, the
surgical end effector 2012 further includes a cutting instrument 2032 and
a sled 2033. The cutting instrument 2032 may be, for example, a knife.
The surgical staple cartridge 2034 operably houses a plurality of
surgical staples (not show) therein that are supported on movable staple
drivers (not shown). As the cutting instrument 2032 is driven distally
through a centrally-disposed slot (not shown) in the surgical staple
cartridge 2034, it forces the sled 2033 distally as well. As the sled
2033 is driven distally, its "wedge-shaped" configuration contacts the
movable staple drivers and drives them vertically toward the closed anvil
2024. The surgical staples are formed as they are driven into the forming
surface located on the underside of the anvil 2024. The sled 2033 may be
part of the surgical staple cartridge 2034, such that when the cutting
instrument 2032 is retracted following the cutting operation, the sled
2033 does not retract. The anvil 2024 may be pivotably opened and closed
at a pivot point 2025 located at the proximal end of the elongated
channel 2022. The anvil 2024 may also include a tab 2027 at its proximal
end that interacts with a component of the mechanical closure system
(described further below) to facilitate the opening of the anvil 2024.
The elongated channel 2022 and the anvil 2024 may be made of an
electrically conductive material (such as metal) so that they may serve
as part of an antenna that communicates with sensor(s) in the end
effector, as described above. The surgical staple cartridge 2034 could be
made of a nonconductive material (such as plastic) and the sensor may be
connected to or disposed in the surgical staple cartridge 2034, as was
also described above.

[0183] As can be seen in FIGS. 22-29, the surgical end effector 2012 is
attached to the tool mounting portion 1300 by an elongated shaft assembly
2008 according to various embodiments. As shown in the illustrated
embodiment, the shaft assembly 2008 includes an articulation joint
generally indicated as 2011 that enables the surgical end effector 2012
to be selectively articulated about an articulation axis AA-AA that is
substantially transverse to a longitudinal tool axis LT-LT. See FIG. 23.
In other embodiments, the articulation joint is omitted. In various
embodiments, the shaft assembly 2008 may include a closure tube assembly
2009 that comprises a proximal closure tube 2040 and a distal closure
tube 2042 that are pivotably linked by a pivot links 2044 and operably
supported on a spine assembly generally depicted as 2049. In the
illustrated embodiment, the spine assembly 2049 comprises a distal spine
portion 2050 that is attached to the elongated channel 2022 and is
pivotally coupled to the proximal spine portion 2052. The closure tube
assembly 2009 is configured to axially slide on the spine assembly 2049
in response to actuation motions applied thereto. The distal closure tube
2042 includes an opening 2045 into which the tab 2027 on the anvil 2024
is inserted in order to facilitate opening of the anvil 2024 as the
distal closure tube 2042 is moved axially in the proximal direction "PD".
The closure tubes 2040, 2042 may be made of electrically conductive
material (such as metal) so that they may serve as part of the antenna,
as described above. Components of the main drive shaft assembly (e.g.,
the drive shafts 2048, 2050) may be made of a nonconductive material
(such as plastic).

[0184] In use, it may be desirable to rotate the surgical end effector
2012 about the longitudinal tool axis LT-LT. In at least one embodiment,
the tool mounting portion 1300 includes a rotational transmission
assembly 2069 that is configured to receive a corresponding rotary output
motion from the tool drive assembly 1010 of the robotic system 1000 and
convert that rotary output motion to a rotary control motion for rotating
the elongated shaft assembly 2008 (and surgical end effector 2012) about
the longitudinal tool axis LT-LT. In various embodiments, for example,
the proximal end 2060 of the proximal closure tube 2040 is rotatably
supported on the tool mounting plate 1302 of the tool mounting portion
1300 by a forward support cradle 1309 and a closure sled 2100 that is
also movably supported on the tool mounting plate 1302. In at least one
form, the rotational transmission assembly 2069 includes a tube gear
segment 2062 that is formed on (or attached to) the proximal end 2060 of
the proximal closure tube 2040 for operable engagement by a rotational
gear assembly 2070 that is operably supported on the tool mounting plate
1302. As can be seen in FIG. 25, the rotational gear assembly 2070, in at
least one embodiment, comprises a rotation drive gear 2072 that is
coupled to a corresponding first one of the driven discs or elements 1304
on the adapter side 1307 of the tool mounting plate 1302 when the tool
mounting portion 1300 is coupled to the tool drive assembly 1010. See
FIG. 22. The rotational gear assembly 2070 further comprises a rotary
driven gear 2074 that is rotatably supported on the tool mounting plate
1302 in meshing engagement with the tube gear segment 2062 and the
rotation drive gear 2072. Application of a first rotary output motion
from the tool drive assembly 1010 of the robotic system 1000 to the
corresponding driven element 1304 will thereby cause rotation of the
rotation drive gear 2072. Rotation of the rotation drive gear 2072
ultimately results in the rotation of the elongated shaft assembly 2008
(and the surgical end effector 2012) about the longitudinal tool axis
LT-LT (represented by arrow "R" in FIG. 25). It will be appreciated that
the application of a rotary output motion from the tool drive assembly
1010 in one direction will result in the rotation of the elongated shaft
assembly 2008 and surgical end effector 2012 about the longitudinal tool
axis LT-LT in a first direction and an application of the rotary output
motion in an opposite direction will result in the rotation of the
elongated shaft assembly 2008 and surgical end effector 2012 in a second
direction that is opposite to the first direction.

[0185] In at least one embodiment, the closure of the anvil 2024 relative
to the staple cartridge 2034 is accomplished by axially moving the
closure tube assembly 2009 in the distal direction "DD" on the spine
assembly 2049. As indicated above, in various embodiments, the proximal
end 2060 of the proximal closure tube 2040 is supported by the closure
sled 2100 which comprises a portion of a closure transmission, generally
depicted as 2099. In at least one form, the closure sled 2100 is
configured to support the closure tube 2009 on the tool mounting plate
1320 such that the proximal closure tube 2040 can rotate relative to the
closure sled 2100, yet travel axially with the closure sled 2100. In
particular, as can be seen in FIG. 30, the closure sled 2100 has an
upstanding tab 2101 that extends into a radial groove 2063 in the
proximal end portion of the proximal closure tube 2040. In addition, as
can be seen in FIGS. 27 and 30, the closure sled 2100 has a tab portion
2102 that extends through a slot 1305 in the tool mounting plate 1302.
The tab portion 2102 is configured to retain the closure sled 2100 in
sliding engagement with the tool mounting plate 1302. In various
embodiments, the closure sled 2100 has an upstanding portion 2104 that
has a closure rack gear 2106 formed thereon. The closure rack gear 2106
is configured for driving engagement with a closure gear assembly 2110.
See FIG. 27.

[0186] In various forms, the closure gear assembly 2110 includes a closure
spur gear 2112 that is coupled to a corresponding second one of the
driven discs or elements 1304 on the adapter side 1307 of the tool
mounting plate 1302. See FIG. 22. Thus, application of a second rotary
output motion from the tool drive assembly 1010 of the robotic system
1000 to the corresponding second driven element 1304 will cause rotation
of the closure spur gear 2112 when the tool mounting portion 1300 is
coupled to the tool drive assembly 1010. The closure gear assembly 2110
further includes a closure reduction gear set 2114 that is supported in
meshing engagement with the closure spur gear 2112. As can be seen in
FIGS. 26 and 27, the closure reduction gear set 2114 includes a driven
gear 2116 that is rotatably supported in meshing engagement with the
closure spur gear 2112. The closure reduction gear set 2114 further
includes a first closure drive gear 2118 that is in meshing engagement
with a second closure drive gear 2120 that is rotatably supported on the
tool mounting plate 1302 in meshing engagement with the closure rack gear
2106. Thus, application of a second rotary output motion from the tool
drive assembly 1010 of the robotic system 1000 to the corresponding
second driven element 1304 will cause rotation of the closure spur gear
2112 and the closure transmission 2110 and ultimately drive the closure
sled 2100 and closure tube assembly 2009 axially. The axial direction in
which the closure tube assembly 2009 moves ultimately depends upon the
direction in which the second driven element 1304 is rotated. For
example, in response to one rotary output motion received from the tool
drive assembly 1010 of the robotic system 1000, the closure sled 2100
will be driven in the distal direction "DD" and ultimately drive the
closure tube assembly 1009 in the distal direction. As the distal closure
tube 2042 is driven distally, the end of the closure tube segment 2042
will engage a portion of the anvil 2024 and cause the anvil 2024 to pivot
to a closed position. Upon application of an "opening" out put motion
from the tool drive assembly 1010 of the robotic system 1000, the closure
sled 2100 and shaft assembly 2008 will be driven in the proximal
direction "PD". As the distal closure tube 2042 is driven in the proximal
direction, the opening 2045 therein interacts with the tab 2027 on the
anvil 2024 to facilitate the opening thereof. In various embodiments, a
spring (not shown) may be employed to bias the anvil to the open position
when the distal closure tube 2042 has been moved to its starting
position. In various embodiments, the various gears of the closure gear
assembly 2110 are sized to generate the necessary closure forces needed
to satisfactorily close the anvil 2024 onto the tissue to be cut and
stapled by the surgical end effector 2012. For example, the gears of the
closure transmission 2110 may be sized to generate approximately 70-120
pounds.

[0187] In various embodiments, the cutting instrument 2032 is driven
through the surgical end effector 2012 by a knife bar 2200. See FIGS. 28
and 30. In at least one form, the knife bar 2200 may be fabricated from,
for example, stainless steel or other similar material and has a
substantially rectangular cross-sectional shape. Such knife bar
configuration is sufficiently rigid to push the cutting instrument 2032
through tissue clamped in the surgical end effector 2012, while still
being flexible enough to enable the surgical end effector 2012 to
articulate relative to the proximal closure tube 2040 and the proximal
spine portion 2052 about the articulation axis AA-AA as will be discussed
in further detail below. As can be seen in FIGS. 31 and 32, the proximal
spine portion 2052 has a rectangular-shaped passage 2054 extending
therethrough to provide support to the knife bar 2200 as it is axially
pushed therethrough. The proximal spine portion 2052 has a proximal end
2056 that is rotatably mounted to a spine mounting bracket 2057 attached
to the tool mounting plate 1032. See FIG. 30. Such arrangement permits
the proximal spine portion 2052 to rotate, but not move axially, within
the proximal closure tube 2040.

[0188] As shown in FIG. 28, the distal end 2202 of the knife bar 2200 is
attached to the cutting instrument 2032. The proximal end 2204 of the
knife bar 2200 is rotatably affixed to a knife rack gear 2206 such that
the knife bar 2200 is free to rotate relative to the knife rack gear
2206. See FIG. 39. As can be seen in FIGS. 24-29, the knife rack gear
2206 is slidably supported within a rack housing 2210 that is attached to
the tool mounting plate 1302 such that the knife rack gear 2206 is
retained in meshing engagement with a knife gear assembly 2220. More
specifically and with reference to FIG. 27, in at least one embodiment,
the knife gear assembly 2220 includes a knife spur gear 2222 that is
coupled to a corresponding third one of the driven discs or elements 1304
on the adapter side 1307 of the tool mounting plate 1302. See FIG. 22.
Thus, application of another rotary output motion from the robotic system
1000 through the tool drive assembly 1010 to the corresponding third
driven element 1304 will cause rotation of the knife spur gear 2222. The
knife gear assembly 2220 further includes a knife gear reduction set 2224
that includes a first knife driven gear 2226 and a second knife drive
gear 2228. The knife gear reduction set 2224 is rotatably mounted to the
tool mounting plate 1302 such that the first knife driven gear 2226 is in
meshing engagement with the knife spur gear 2222. Likewise, the second
knife drive gear 2228 is in meshing engagement with a third knife drive
gear 2230 that is rotatably supported on the tool mounting plate 1302 in
meshing engagement with the knife rack gear 2206. In various embodiments,
the gears of the knife gear assembly 2220 are sized to generate the
forces needed to drive the cutting element 2032 through the tissue
clamped in the surgical end effector 2012 and actuate the staples
therein. For example, the gears of the knife drive assembly 2230 may be
sized to generate approximately 40 to 100 pounds. It will be appreciated
that the application of a rotary output motion from the tool drive
assembly 1010 in one direction will result in the axial movement of the
cutting instrument 2032 in a distal direction and application of the
rotary output motion in an opposite direction will result in the axial
travel of the cutting instrument 2032 in a proximal direction.

[0189] In various embodiments, the surgical tool 1200 employs and
articulation system 2007 that includes an articulation joint 2011 that
enables the surgical end effector 2012 to be articulated about an
articulation axis AA-AA that is substantially transverse to the
longitudinal tool axis LT-LT. In at least one embodiment, the surgical
tool 1200 includes first and second articulation bars 2250a, 2250b that
are slidably supported within corresponding passages 2053 provided
through the proximal spine portion 2052. See FIGS. 30 and 32. In at least
one form, the first and second articulation bars 2250a, 2250b are
actuated by an articulation transmission generally designated as 2249
that is operably supported on the tool mounting plate 1032. Each of the
articulation bars 2250a, 2250b has a proximal end 2252 that has a guide
rod protruding therefrom which extend laterally through a corresponding
slot in the proximal end portion of the proximal spine portion 2052 and
into a corresponding arcuate slot in an articulation nut 2260 which
comprises a portion of the articulation transmission. FIG. 40 illustrates
articulation bar 2250a. It will be understood that articulation bar 2250b
is similarly constructed. As can be seen in FIG. 31, for example, the
articulation bar 2250a has a guide rod 2254 which extends laterally
through a corresponding slot 2058 in the proximal end portion 2056 of the
distal spine portion 2050 and into a corresponding arcuate slot 2262 in
the articulation nut 2260. In addition, the articulation bar 2250a has a
distal end 2251a that is pivotally coupled to the distal spine portion
2050 by, for example, a pin 2253a and articulation bar 2250b has a distal
end 2251b that is pivotally coupled to the distal spine portion 2050 by,
for example, a pin 2253b. In particular, the articulation bar 2250a is
laterally offset in a first lateral direction from the longitudinal tool
axis LT-LT and the articulation bar 2250b is laterally offset in a second
lateral direction from the longitudinal tool axis LT-LT. Thus, axial
movement of the articulation bars 2250a and 2250b in opposing directions
will result in the articulation of the distal spine portion 2050 as well
as the surgical end effector 2012 attached thereto about the articulation
axis AA-AA as will be discussed in further detail below.

[0190] Articulation of the surgical end effector 2012 is controlled by
rotating the articulation nut 2260 about the longitudinal tool axis
LT-LT. The articulation nut 2260 is rotatably journaled on the proximal
end portion 2056 of the distal spine portion 2050 and is rotatably driven
thereon by an articulation gear assembly 2270. More specifically and with
reference to FIG. 25, in at least one embodiment, the articulation gear
assembly 2270 includes an articulation spur gear 2272 that is coupled to
a corresponding fourth one of the driven discs or elements 1304 on the
adapter side 1307 of the tool mounting plate 1302. See FIG. 22. Thus,
application of another rotary input motion from the robotic system 1000
through the tool drive assembly 1010 to the corresponding fourth driven
element 1304 will cause rotation of the articulation spur gear 2272 when
the interface 1230 is coupled to the tool holder 1270. An articulation
drive gear 2274 is rotatably supported on the tool mounting plate 1302 in
meshing engagement with the articulation spur gear 2272 and a gear
portion 2264 of the articulation nut 2260 as shown. As can be seen in
FIGS. 30 and 31, the articulation nut 2260 has a shoulder 2266 formed
thereon that defines an annular groove 2267 for receiving retaining posts
2268 therein. Retaining posts 2268 are attached to the tool mounting
plate 1302 and serve to prevent the articulation nut 2260 from moving
axially on the proximal spine portion 2052 while maintaining the ability
to be rotated relative thereto. Thus, rotation of the articulation nut
2260 in a first direction, will result in the axial movement of the
articulation bar 2250a in a distal direction "DD" and the axial movement
of the articulation bar 2250b in a proximal direction "PD" because of the
interaction of the guide rods 2254 with the spiral slots 2262 in the
articulation gear 2260. Similarly, rotation of the articulation nut 2260
in a second direction that is opposite to the first direction will result
in the axial movement of the articulation bar 2250a in the proximal
direction "PD" as well as cause articulation bar 2250b to axially move in
the distal direction "DD". Thus, the surgical end effector 2012 may be
selectively articulated about articulation axis "AA-AA" in a first
direction "FD" by simultaneously moving the articulation bar 2250a in the
distal direction "DD" and the articulation bar 2250b in the proximal
direction "PD". Likewise, the surgical end effector 2012 may be
selectively articulated about the articulation axis "AA-AA" in a second
direction "SD" by simultaneously moving the articulation bar 2250a in the
proximal direction "PD" and the articulation bar 2250b in the distal
direction "DD." See FIG. 23.

[0191] The tool embodiment described above employs an interface
arrangement that is particularly well-suited for mounting the robotically
controllable medical tool onto at least one form of robotic arm
arrangement that generates at least four different rotary control
motions. Those of ordinary skill in the art will appreciate that such
rotary output motions may be selectively controlled through the
programmable control systems employed by the robotic system/controller.
For example, the tool arrangement described above may be well-suited for
use with those robotic systems manufactured by Intuitive Surgical, Inc.
of Sunnyvale, Calif., U.S.A., many of which may be described in detail in
various patents incorporated herein by reference. The unique and novel
aspects of various embodiments of the present invention serve to utilize
the rotary output motions supplied by the robotic system to generate
specific control motions having sufficient magnitudes that enable end
effectors to cut and staple tissue. Thus, the unique arrangements and
principles of various embodiments of the present invention may enable a
variety of different forms of the tool systems disclosed and claimed
herein to be effectively employed in connection with other types and
forms of robotic systems that supply programmed rotary or other output
motions. In addition, as will become further apparent as the present
Detailed Description proceeds, various end effector embodiments of the
present invention that require other forms of actuation motions may also
be effectively actuated utilizing one or more of the control motions
generated by the robotic system.

[0192] FIGS. 34-38 illustrate yet another surgical tool 2300 that may be
effectively employed in connection with the robotic system 1000 that has
a tool drive assembly that is operably coupled to a controller of the
robotic system that is operable by inputs from an operator and which is
configured to provide at least one rotary output motion to at least one
rotatable body portion supported on the tool drive assembly. In various
forms, the surgical tool 2300 includes a surgical end effector 2312 that
includes an elongated channel 2322 and a pivotally translatable clamping
member, such as an anvil 2324, which are maintained at a spacing that
assures effective stapling and severing of tissue clamped in the surgical
end effector 2312. As shown in the illustrated embodiment, the surgical
end effector 2312 may include, in addition to the previously-mentioned
elongated channel 2322 and anvil 2324, a cutting instrument 2332 that has
a sled portion 2333 formed thereon, a surgical staple cartridge 2334 that
is seated in the elongated channel 2322, and a rotary end effector drive
shaft 2336 that has a helical screw thread formed thereon. The cutting
instrument 2332 may be, for example, a knife. As will be discussed in
further detail below, rotation of the end effector drive shaft 2336 will
cause the cutting instrument 2332 and sled portion 2333 to axially travel
through the surgical staple cartridge 2334 to move between a starting
position and an ending position. The direction of axial travel of the
cutting instrument 2332 depends upon the direction in which the end
effector drive shaft 2336 is rotated. The anvil 2324 may be pivotably
opened and closed at a pivot point 2325 connected to the proximate end of
the elongated channel 2322. The anvil 2324 may also include a tab 2327 at
its proximate end that operably interfaces with a component of the
mechanical closure system (described further below) to open and close the
anvil 2324. When the end effector drive shaft 2336 is rotated, the
cutting instrument 2332 and sled 2333 will travel longitudinally through
the surgical staple cartridge 2334 from the starting position to the
ending position, thereby cutting tissue clamped within the surgical end
effector 2312. The movement of the sled 2333 through the surgical staple
cartridge 2334 causes the staples therein to be driven through the
severed tissue and against the closed anvil 2324, which turns the staples
to fasten the severed tissue. In one form, the elongated channel 2322 and
the anvil 2324 may be made of an electrically conductive material (such
as metal) so that they may serve as part of the antenna that communicates
with sensor(s) in the end effector, as described above. The surgical
staple cartridge 2334 could be made of a nonconductive material (such as
plastic) and the sensor may be connected to or disposed in the surgical
staple cartridge 2334, as described above.

[0193] It should be noted that although the embodiments of the surgical
tool 2300 described herein employ a surgical end effector 2312 that
staples the severed tissue, in other embodiments different techniques for
fastening or sealing the severed tissue may be used. For example, end
effectors that use RF energy or adhesives to fasten the severed tissue
may also be used. U.S. Pat. No. 5,709,680, entitled "Electrosurgical
Hemostatic Device" to Yates et al., and U.S. Pat. No. 5,688,270, entitled
"Electrosurgical Hemostatic Device With Recessed And/Or Offset
Electrodes" to Yates et al., which are incorporated herein by reference,
discloses cutting instruments that use RF energy to fasten the severed
tissue. U.S. patent application Ser. No. 11/267,811 to Morgan et al. and
U.S. patent application Ser. No. 11/267,363 to Shelton et al., which are
also incorporated herein by reference, disclose cutting instruments that
use adhesives to fasten the severed tissue. Accordingly, although the
description herein refers to cutting/stapling operations and the like, it
should be recognized that this is an exemplary embodiment and is not
meant to be limiting. Other tissue-fastening techniques may also be used.

[0194] In the illustrated embodiment, the surgical end effector 2312 is
coupled to an elongated shaft assembly 2308 that is coupled to a tool
mounting portion 2460 and defines a longitudinal tool axis LT-LT. In this
embodiment, the elongated shaft assembly 2308 does not include an
articulation joint. Those of ordinary skill in the art will understand
that other embodiments may have an articulation joint therein. In at
least one embodiment, the elongated shaft assembly 2308 comprises a
hollow outer tube 2340 that is rotatably supported on a tool mounting
plate 2462 of a tool mounting portion 2460 as will be discussed in
further detail below. In various embodiments, the elongated shaft
assembly 2308 further includes a distal spine shaft 2350. Distal spine
shaft 2350 has a distal end portion 2354 that is coupled to, or otherwise
integrally formed with, a distal stationary base portion 2360 that is
non-movably coupled to the channel 2322. See FIGS. 35-37.

[0195] As shown in FIG. 35, the distal spine shaft 2350 has a proximal end
portion 2351 that is slidably received within a slot 2355 in a proximal
spine shaft 2353 that is non-movably supported within the hollow outer
tube 2340 by at least one support collar 2357. As can be further seen in
FIGS. 35 and 36, the surgical tool 2300 includes a closure tube 2370 that
is constrained to only move axially relative to the distal stationary
base portion 2360. The closure tube 2370 has a proximal end 2372 that has
an internal thread 2374 formed therein that is in threaded engagement
with a transmission arrangement, generally depicted as 2375 that is
operably supported on the tool mounting plate 2462. In various forms, the
transmission arrangement 2375 includes a rotary drive shaft assembly,
generally designated as 2381. When rotated, the rotary drive shaft
assembly 2381 will cause the closure tube 2370 to move axially as will be
describe in further detail below. In at least one form, the rotary drive
shaft assembly 2381 includes a closure drive nut 2382 of a closure clutch
assembly generally designated as 2380. More specifically, the closure
drive nut 2382 has a proximal end portion 2384 that is rotatably
supported relative to the outer tube 2340 and is in threaded engagement
with the closure tube 2370. For assembly purposes, the proximal end
portion 2384 may be threadably attached to a retention ring 2386.
Retention ring 2386, in cooperation with an end 2387 of the closure drive
nut 2382, defines an annular slot 2388 into which a shoulder 2392 of a
locking collar 2390 extends. The locking collar 2390 is non-movably
attached (e.g., welded, glued, etc.) to the end of the outer tube 2340.
Such arrangement serves to affix the closure drive nut 2382 to the outer
tube 2340 while enabling the closure drive nut 2382 to rotate relative to
the outer tube 2340. The closure drive nut 2382 further has a distal end
2383 that has a threaded portion 2385 that threadably engages the
internal thread 2374 of the closure tube 2370. Thus, rotation of the
closure drive nut 2382 will cause the closure tube 2370 to move axially
as represented by arrow "D" in FIG. 36.

[0196] Closure of the anvil 2324 and actuation of the cutting instrument
2332 are accomplished by control motions that are transmitted by a hollow
drive sleeve 2400. As can be seen in FIGS. 35 and 36, the hollow drive
sleeve 2400 is rotatably and slidably received on the distal spine shaft
2350. The drive sleeve 2400 has a proximal end portion 2401 that is
rotatably mounted to the proximal spine shaft 2353 that protrudes from
the tool mounting portion 2460 such that the drive sleeve 2400 may rotate
relative thereto. See FIG. 35. As can also be seen in FIGS. 35-37, the
drive sleeve 2400 is rotated about the longitudinal tool axis "LT-LT" by
a drive shaft 2440. The drive shaft 2440 has a drive gear 2444 that is
attached to its distal end 2442 and is in meshing engagement with a
driven gear 2450 that is attached to the drive sleeve 2400.

[0197] The drive sleeve 2400 further has a distal end portion 2402 that is
coupled to a closure clutch 2410 portion of the closure clutch assembly
2380 that has a proximal face 2412 and a distal face 2414. The proximal
face 2412 has a series of proximal teeth 2416 formed thereon that are
adapted for selective engagement with corresponding proximal teeth
cavities 2418 formed in the proximal end portion 2384 of the closure
drive nut 2382. Thus, when the proximal teeth 2416 are in meshing
engagement with the proximal teeth cavities 2418 in the closure drive nut
2382, rotation of the drive sleeve 2400 will result in rotation of the
closure drive nut 2382 and ultimately cause the closure tube 2370 to move
axially as will be discussed in further detail below.

[0198] As can be most particularly seen in FIGS. 35 and 36, the distal
face 2414 of the drive clutch portion 2410 has a series of distal teeth
2415 formed thereon that are adapted for selective engagement with
corresponding distal teeth cavities 2426 formed in a face plate portion
2424 of a knife drive shaft assembly 2420. In various embodiments, the
knife drive shaft assembly 2420 comprises a hollow knife shaft segment
2430 that is rotatably received on a corresponding portion of the distal
spine shaft 2350 that is attached to or protrudes from the stationary
base 2360. When the distal teeth 2415 of the closure clutch portion 2410
are in meshing engagement with the distal teeth cavities 2426 in the face
plate portion 2424, rotation of the drive sleeve 2400 will result in
rotation of the drive shaft segment 2430 about the stationary shaft 2350.
As can be seen in FIGS. 35-37, a knife drive gear 2432 is attached to the
drive shaft segment 2430 and is meshing engagement with a drive knife
gear 2434 that is attached to the end effector drive shaft 2336. Thus,
rotation of the drive shaft segment 2430 will result in the rotation of
the end effector drive shaft 2336 to drive the cutting instrument 2332
and sled 2333 distally through the surgical staple cartridge 2334 to cut
and staple tissue clamped within the surgical end effector 2312. The sled
2333 may be made of, for example, plastic, and may have a sloped distal
surface. As the sled 2333 traverses the elongated channel 2322, the
sloped forward surface of the sled 2333 pushes up or "drive" the staples
in the surgical staple cartridge 2334 through the clamped tissue and
against the anvil 2324. The anvil 2324 turns or "forms" the staples,
thereby stapling the severed tissue. As used herein, the term "fire"
refers to the initiation of actions required to drive the cutting
instrument and sled portion in a distal direction through the surgical
staple cartridge to cut the tissue clamped in the surgical end effector
and drive the staples through the severed tissue.

[0199] In use, it may be desirable to rotate the surgical end effector
2312 about the longitudinal tool axis LT-LT. In at least one embodiment,
the transmission arrangement 2375 includes a rotational transmission
assembly 2465 that is configured to receive a corresponding rotary output
motion from the tool drive assembly 1010 of the robotic system 1000 and
convert that rotary output motion to a rotary control motion for rotating
the elongated shaft assembly 2308 (and surgical end effector 2312) about
the longitudinal tool axis LT-LT. As can be seen in FIG. 38, a proximal
end 2341 of the outer tube 2340 is rotatably supported within a cradle
arrangement 2343 attached to the tool mounting plate 2462 of the tool
mounting portion 2460. A rotation gear 2345 is formed on or attached to
the proximal end 2341 of the outer tube 2340 of the elongated shaft
assembly 2308 for meshing engagement with a rotation gear assembly 2470
operably supported on the tool mounting plate 2462. In at least one
embodiment, a rotation drive gear 2472 is coupled to a corresponding
first one of the driven discs or elements 1304 on the adapter side of the
tool mounting plate 2462 when the tool mounting portion 2460 is coupled
to the tool drive assembly 1010. See FIGS. 22 and 38. The rotation drive
assembly 2470 further comprises a rotary driven gear 2474 that is
rotatably supported on the tool mounting plate 2462 in meshing engagement
with the rotation gear 2345 and the rotation drive gear 2472. Application
of a first rotary output motion from the robotic system 1000 through the
tool drive assembly 1010 to the corresponding driven element 1304 will
thereby cause rotation of the rotation drive gear 2472 by virtue of being
operably coupled thereto. Rotation of the rotation drive gear 2472
ultimately results in the rotation of the elongated shaft assembly 2308
(and the end effector 2312) about the longitudinal tool axis LT-LT
(primary rotary motion).

[0200] Closure of the anvil 2324 relative to the staple cartridge 2034 is
accomplished by axially moving the closure tube 2370 in the distal
direction "DD". Axial movement of the closure tube 2370 in the distal
direction "DD" is accomplished by applying a rotary control motion to the
closure drive nut 2382. To apply the rotary control motion to the closure
drive nut 2382, the closure clutch 2410 must first be brought into
meshing engagement with the proximal end portion 2384 of the closure
drive nut 2382. In various embodiments, the transmission arrangement 2375
further includes a shifter drive assembly 2480 that is operably supported
on the tool mounting plate 2462. More specifically and with reference to
FIG. 38, it can be seen that a proximal end portion 2359 of the proximal
spine portion 2353 extends through the rotation gear 2345 and is
rotatably coupled to a shifter gear rack 2481 that is slidably affixed to
the tool mounting plate 2462 through slots 2482. The shifter drive
assembly 2480 further comprises a shifter drive gear 2483 that is coupled
to a corresponding second one of the driven discs or elements 1304 on the
adapter side of the tool mounting plate 2462 when the tool mounting
portion 2460 is coupled to the tool holder 1270. See FIGS. 22 and 38. The
shifter drive assembly 2480 further comprises a shifter driven gear 2478
that is rotatably supported on the tool mounting plate 2462 in meshing
engagement with the shifter drive gear 2483 and the shifter rack gear
2482. Application of a second rotary output motion from the robotic
system 1000 through the tool drive assembly 1010 to the corresponding
driven element 1304 will thereby cause rotation of the shifter drive gear
2483 by virtue of being operably coupled thereto. Rotation of the shifter
drive gear 2483 ultimately results in the axial movement of the shifter
gear rack 2482 and the proximal spine portion 2353 as well as the drive
sleeve 2400 and the closure clutch 2410 attached thereto. The direction
of axial travel of the closure clutch 2410 depends upon the direction in
which the shifter drive gear 2483 is rotated by the robotic system 1000.
Thus, rotation of the shifter drive gear 2483 in a first rotary direction
will result in the axial movement of the closure clutch 2410 in the
proximal direction "PD" to bring the proximal teeth 2416 into meshing
engagement with the proximal teeth cavities 2418 in the closure drive nut
2382. Conversely, rotation of the shifter drive gear 2483 in a second
rotary direction (opposite to the first rotary direction) will result in
the axial movement of the closure clutch 2410 in the distal direction
"DD" to bring the distal teeth 2415 into meshing engagement with
corresponding distal teeth cavities 2426 formed in the face plate portion
2424 of the knife drive shaft assembly 2420.

[0201] Once the closure clutch 2410 has been brought into meshing
engagement with the closure drive nut 2382, the closure drive nut 2382 is
rotated by rotating the closure clutch 2410. Rotation of the closure
clutch 2410 is controlled by applying rotary output motions to a rotary
drive transmission portion 2490 of transmission arrangement 2375 that is
operably supported on the tool mounting plate 2462 as shown in FIG. 38.
In at least one embodiment, the rotary drive transmission 2490 includes a
rotary drive assembly 2490' that includes a gear 2491 that is coupled to
a corresponding third one of the driven discs or elements 1304 on the
adapter side of the tool mounting plate 2462 when the tool mounting
portion 2460 is coupled to the tool holder 1270. See FIGS. 22 and 38. The
rotary drive transmission 2490 further comprises a first rotary driven
gear 2492 that is rotatably supported on the tool mounting plate 2462 in
meshing engagement with a second rotary driven gear 2493 and the rotary
drive gear 2491. The second rotary driven gear 2493 is coupled to a
proximal end portion 2443 of the drive shaft 2440.

[0202] Rotation of the rotary drive gear 2491 in a first rotary direction
will result in the rotation of the drive shaft 2440 in a first direction.
Conversely, rotation of the rotary drive gear 2491 in a second rotary
direction (opposite to the first rotary direction) will cause the drive
shaft 2440 to rotate in a second direction. As indicated above, the drive
shaft 2440 has a drive gear 2444 that is attached to its distal end 2442
and is in meshing engagement with a driven gear 2450 that is attached to
the drive sleeve 2400. Thus, rotation of the drive shaft 2440 results in
rotation of the drive sleeve 2400.

[0203] A method of operating the surgical tool 2300 will now be described.
Once the tool mounting portion 2462 has been operably coupled to the tool
holder 1270 of the robotic system 1000 and oriented into position
adjacent the target tissue to be cut and stapled, if the anvil 2334 is
not already in the open position (FIG. 35), the robotic system 1000 may
apply the first rotary output motion to the shifter drive gear 2483 which
results in the axial movement of the closure clutch 2410 into meshing
engagement with the closure drive nut 2382 (if it is not already in
meshing engagement therewith). See FIG. 36. Once the controller 1001 of
the robotic system 1000 has confirmed that the closure clutch 2410 is
meshing engagement with the closure drive nut 2382 (e.g., by means of
sensor(s)) in the surgical end effector 2312 that are in communication
with the robotic control system), the robotic controller 1001 may then
apply a second rotary output motion to the rotary drive gear 2492 which,
as was described above, ultimately results in the rotation of the rotary
drive nut 2382 in the first direction which results in the axial travel
of the closure tube 2370 in the distal direction "DD". As the closure
tube 2370 moved in the distal direction, it contacts a portion of the
anvil 2323 and causes the anvil 2324 to pivot to the closed position to
clamp the target tissue between the anvil 2324 and the surgical staple
cartridge 2334. Once the robotic controller 1001 determines that the
anvil 2334 has been pivoted to the closed position by corresponding
sensor(s) in the surgical end effector 2312 in communication therewith,
the robotic system 1000 discontinues the application of the second rotary
output motion to the rotary drive gear 2491. The robotic controller 1001
may also provide the surgeon with an indication that the anvil 2334 has
been fully closed. The surgeon may then initiate the firing procedure. In
alternative embodiments, the firing procedure may be automatically
initiated by the robotic controller 1001. The robotic controller 1001
then applies the primary rotary control motion 2483 to the shifter drive
gear 2483 which results in the axial movement of the closure clutch 2410
into meshing engagement with the face plate portion 2424 of the knife
drive shaft assembly 2420. See FIG. 46. Once the controller 1001 of the
robotic system 1000 has confirmed that the closure clutch 2410 is meshing
engagement with the face plate portion 2424 (by means of sensor(s)) in
the end effector 2312 that are in communication with the robotic
controller 1001), the robotic controller 1001 may then apply the second
rotary output motion to the rotary drive gear 2492 which, as was
described above, ultimately results in the axial movement of the cutting
instrument 2332 and sled portion 2333 in the distal direction "DD"
through the surgical staple cartridge 2334. As the cutting instrument
2332 moves distally through the surgical staple cartridge 2334, the
tissue clamped therein is severed. As the sled portion 2333 is driven
distally, it causes the staples within the surgical staple cartridge to
be driven through the severed tissue into forming contact with the anvil
2324. Once the robotic controller 1001 has determined that the cutting
instrument 2324 has reached the end position within the surgical staple
cartridge 2334 (by means of sensor(s)) in the end effector 2312 that are
in communication with the robotic controller 1001), the robotic
controller 1001 discontinues the application of the second rotary output
motion to the rotary drive gear 2491. Thereafter, the robotic controller
1001 applies the secondary rotary output motion to the rotary drive gear
2491 which ultimately results in the axial travel of the cutting
instrument 2332 and sled portion 2333 in the proximal direction "PD" to
the starting position. Once the robotic controller 1001 has determined
that the cutting instrument 2324 has reached the starting position by
means of sensor(s) in the surgical end effector 2312 that are in
communication with the robotic controller 1001, the robotic controller
1001 discontinues the application of the secondary rotary output motion
to the rotary drive gear 2491. Thereafter, the robotic controller 1001
applies the primary rotary output motion to the shifter drive gear 2483
to cause the closure clutch 2410 to move into engagement with the rotary
drive nut 2382. Once the closure clutch 2410 has been moved into meshing
engagement with the rotary drive nut 2382, the robotic controller 1001
then applies the secondary output motion to the rotary drive gear 2491
which ultimately results in the rotation of the rotary drive nut 2382 in
the second direction to cause the closure tube 2370 to move in the
proximal direction "PD". As can be seen in FIGS. 35-37, the closure tube
2370 has an opening 2345 therein that engages the tab 2327 on the anvil
2324 to cause the anvil 2324 to pivot to the open position. In
alternative embodiments, a spring may also be employed to pivot the anvil
2324 to the open position when the closure tube 2370 has been returned to
the starting position (FIG. 35).

[0204] FIGS. 39-43 illustrate yet another surgical tool 2500 that may be
effectively employed in connection with the robotic system 1000. In
various forms, the surgical tool 2500 includes a surgical end effector
2512 that includes a "first portion" in the form of an elongated channel
2522 and a "second movable portion" in the form of a pivotally
translatable clamping member, such as an anvil 2524, which are maintained
at a spacing that assures effective stapling and severing of tissue
clamped in the surgical end effector 2512. As shown in the illustrated
embodiment, the surgical end effector 2512 may include, in addition to
the previously-mentioned elongated channel 2522 and anvil 2524, a "third
movable portion" in the form of a cutting instrument 2532, a sled (not
shown), and a surgical staple cartridge 2534 that is removably seated in
the elongated channel 2522. The cutting instrument 2532 may be, for
example, a knife. The anvil 2524 may be pivotably opened and closed at a
pivot point 2525 connected to the proximate end of the elongated channel
2522. The anvil 2524 may also include a tab 2527 at its proximate end
that is configured to operably interface with a component of the
mechanical closure system (described further below) to open and close the
anvil 2524. When actuated, the knife 2532 and sled travel longitudinally
along the elongated channel 2522, thereby cutting tissue clamped within
the surgical end effector 2512. The movement of the sled along the
elongated channel 2522 causes the staples of the surgical staple
cartridge 2534 to be driven through the severed tissue and against the
closed anvil 2524, which turns the staples to fasten the severed tissue.
In one form, the elongated channel 2522 and the anvil 2524 may be made of
an electrically conductive material (such as metal) so that they may
serve as part of the antenna that communicates with sensor(s) in the
surgical end effector, as described above. The surgical staple cartridge
2534 could be made of a nonconductive material (such as plastic) and the
sensor may be connected to or disposed in the surgical staple cartridge
2534, as described above.

[0205] It should be noted that although the embodiments of the surgical
tool 2500 described herein employ a surgical end effector 2512 that
staples the severed tissue, in other embodiments different techniques for
fastening or sealing the severed tissue may be used. For example, end
effectors that use RF energy or adhesives to fasten the severed tissue
may also be used. U.S. Pat. No. 5,709,680, entitled "Electrosurgical
Hemostatic Device" to Yates et al., and U.S. Pat. No. 5,688,270, entitled
"Electrosurgical Hemostatic Device With Recessed And/Or Offset
Electrodes" to Yates et al., which are incorporated herein by reference,
discloses cutting instruments that use RF energy to fasten the severed
tissue. U.S. patent application Ser. No. 11/267,811 to Morgan et al. and
U.S. patent application Ser. No. 11/267,363 to Shelton et al., which are
also incorporated herein by reference, disclose cutting instruments that
use adhesives to fasten the severed tissue. Accordingly, although the
description herein refers to cutting/stapling operations and the like, it
should be recognized that this is an exemplary embodiment and is not
meant to be limiting. Other tissue-fastening techniques may also be used.

[0206] In the illustrated embodiment, the elongated channel 2522 of the
surgical end effector 2512 is coupled to an elongated shaft assembly 2508
that is coupled to a tool mounting portion 2600. In at least one
embodiment, the elongated shaft assembly 2508 comprises a hollow spine
tube 2540 that is non-movably coupled to a tool mounting plate 2602 of
the tool mounting portion 2600. As can be seen in FIGS. 40 and 41, the
proximal end 2523 of the elongated channel 2522 comprises a hollow
tubular structure configured to be attached to the distal end 2541 of the
spine tube 2540. In one embodiment, for example, the proximal end 2523 of
the elongated channel 2522 is welded or glued to the distal end of the
spine tube 2540.

[0207] As can be further seen in FIGS. 40 and 41, in at least one
non-limiting embodiment, the surgical tool 2500 further includes an
axially movable actuation member in the form of a closure tube 2550 that
is constrained to move axially relative to the elongated channel 2522 and
the spine tube 1540. The closure tube 2550 has a proximal end 2552 that
has an internal thread 2554 formed therein that is in threaded engagement
with a rotatably movable portion in the form of a closure drive nut 2560.
More specifically, the closure drive nut 2560 has a proximal end portion
2562 that is rotatably supported relative to the elongated channel 2522
and the spine tube 2540. For assembly purposes, the proximal end portion
2562 is threadably attached to a retention ring 2570. The retention ring
2570 is received in a groove 2529 formed between a shoulder 2527 on the
proximal end 2523 of the elongated channel 2522 and the distal end 2541
of the spine tube 1540. Such arrangement serves to rotatably support the
closure drive nut 2560 within the elongated channel 2522. Rotation of the
closure drive nut 2560 will cause the closure tube 2550 to move axially
as represented by arrow "D" in FIG. 40.

[0208] Extending through the spine tube 2540 and the closure drive nut
2560 is a drive member which, in at least one embodiment, comprises a
knife bar 2580 that has a distal end portion 2582 that is rotatably
coupled to the cutting instrument 2532 such that the knife bar 2580 may
rotate relative to the cutting instrument 2582. As can be seen in FIG.
40-42, the closure drive nut 2560 has a slot 2564 therein through which
the knife bar 2580 can slidably extend. Such arrangement permits the
knife bar 2580 to move axially relative to the closure drive nut 2560.
However, rotation of the knife bar 2580 about the longitudinal tool axis
LT-LT will also result in the rotation of the closure drive nut 2560. The
axial direction in which the closure tube 2550 moves ultimately depends
upon the direction in which the knife bar 2580 and the closure drive nut
2560 are rotated. As the closure tube 2550 is driven distally, the distal
end thereof will contact the anvil 2524 and cause the anvil 2524 to pivot
to a closed position. Upon application of an opening rotary output motion
from the robotic system 1000, the closure tube 2550 will be driven in the
proximal direction "PD" and pivot the anvil 2524 to the open position by
virtue of the engagement of the tab 2527 with the opening 2555 in the
closure tube 2550.

[0209] In use, it may be desirable to rotate the surgical end effector
2512 about the longitudinal tool axis LT-LT. In at least one embodiment,
the tool mounting portion 2600 is configured to receive a corresponding
first rotary output motion from the robotic system 1000 and convert that
first rotary output motion to a rotary control motion for rotating the
elongated shaft assembly 2508 about the longitudinal tool axis LT-LT. As
can be seen in FIG. 38, a proximal end 2542 of the hollow spine tube 2540
is rotatably supported within a cradle arrangement 2603 attached to a
tool mounting plate 2602 of the tool mounting portion 2600. Various
embodiments of the surgical tool 2500 further include a transmission
arrangement, generally depicted as 2605, that is operably supported on
the tool mounting plate 2602. In various forms the transmission
arrangement 2605 include a rotation gear 2544 that is formed on or
attached to the proximal end 2542 of the spine tube 2540 for meshing
engagement with a rotation drive assembly 2610 that is operably supported
on the tool mounting plate 2602. In at least one embodiment, a rotation
drive gear 2612 is coupled to a corresponding first one of the rotational
bodies, driven discs or elements 1304 on the adapter side of the tool
mounting plate 2602 when the tool mounting portion 2600 is coupled to the
tool holder 1270. See FIGS. 22 and 43. The rotation drive assembly 2610
further comprises a rotary driven gear 2614 that is rotatably supported
on the tool mounting plate 2602 in meshing engagement with the rotation
gear 2544 and the rotation drive gear 2612. Application of a first rotary
output motion from the robotic system 1000 through the tool drive
assembly 1010 to the corresponding driven rotational body 1304 will
thereby cause rotation of the rotation drive gear 2612 by virtue of being
operably coupled thereto. Rotation of the rotation drive gear 2612
ultimately results in the rotation of the elongated shaft assembly 2508
(and the end effector 2512) about the longitudinal tool axis LT-LT.

[0210] Closure of the anvil 2524 relative to the surgical staple cartridge
2534 is accomplished by axially moving the closure tube 2550 in the
distal direction "DD". Axial movement of the closure tube 2550 in the
distal direction "DD" is accomplished by applying a rotary control motion
to the closure drive nut 2382. In various embodiments, the closure drive
nut 2560 is rotated by applying a rotary output motion to the knife bar
2580. Rotation of the knife bar 2580 is controlled by applying rotary
output motions to a rotary closure system 2620 that is operably supported
on the tool mounting plate 2602 as shown in FIG. 43. In at least one
embodiment, the rotary closure system 2620 includes a closure drive gear
2622 that is coupled to a corresponding second one of the driven
rotatable body portions discs or elements 1304 on the adapter side of the
tool mounting plate 2462 when the tool mounting portion 2600 is coupled
to the tool holder 1270. See FIGS. 22 and 43. The closure drive gear
2622, in at least one embodiment, is in meshing driving engagement with a
closure gear train, generally depicted as 2623. The closure gear drive
rain 2623 comprises a first driven closure gear 2624 that is rotatably
supported on the tool mounting plate 2602. The first closure driven gear
2624 is attached to a second closure driven gear 2626 by a drive shaft
2628. The second closure driven gear 2626 is in meshing engagement with a
third closure driven gear 2630 that is rotatably supported on the tool
mounting plate 2602. Rotation of the closure drive gear 2622 in a second
rotary direction will result in the rotation of the third closure driven
gear 2630 in a second direction. Conversely, rotation of the closure
drive gear 2483 in a secondary rotary direction (opposite to the second
rotary direction) will cause the third closure driven gear 2630 to rotate
in a secondary direction.

[0211] As can be seen in FIG. 43, a drive shaft assembly 2640 is coupled
to a proximal end of the knife bar 2580. In various embodiments, the
drive shaft assembly 2640 includes a proximal portion 2642 that has a
square cross-sectional shape. The proximal portion 2642 is configured to
slideably engage a correspondingly shaped aperture in the third driven
gear 2630. Such arrangement results in the rotation of the drive shaft
assembly 2640 (and knife bar 2580) when the third driven gear 2630 is
rotated. The drive shaft assembly 2640 is axially advanced in the distal
and proximal directions by a knife drive assembly 2650. One form of the
knife drive assembly 2650 comprises a rotary drive gear 2652 that is
coupled to a corresponding third one of the driven rotatable body
portions, discs or elements 1304 on the adapter side of the tool mounting
plate 2462 when the tool mounting portion 2600 is coupled to the tool
holder 1270. See FIGS. 22 and 43. The rotary driven gear 2652 is in
meshing driving engagement with a gear train, generally depicted as 2653.
In at least one form, the gear train 2653 further comprises a first
rotary driven gear assembly 2654 that is rotatably supported on the tool
mounting plate 2602. The first rotary driven gear assembly 2654 is in
meshing engagement with a third rotary driven gear assembly 2656 that is
rotatably supported on the tool mounting plate 2602 and which is in
meshing engagement with a fourth rotary driven gear assembly 2658 that is
in meshing engagement with a threaded portion 2644 of the drive shaft
assembly 2640. Rotation of the rotary drive gear 2652 in a third rotary
direction will result in the axial advancement of the drive shaft
assembly 2640 and knife bar 2580 in the distal direction "DD".
Conversely, rotation of the rotary drive gear 2652 in a tertiary rotary
direction (opposite to the third rotary direction) will cause the drive
shaft assembly 2640 and the knife bar 2580 to move in the proximal
direction.

[0212] A method of operating the surgical tool 2500 will now be described.
Once the tool mounting portion 2600 has been operably coupled to the tool
holder 1270 of the robotic system 1000, the robotic system 1000 can
orient the surgical end effector 2512 in position adjacent the target
tissue to be cut and stapled. If the anvil 2524 is not already in the
open position (FIG. 49), the robotic system 1000 may apply the second
rotary output motion to the closure drive gear 2622 which results in the
rotation of the knife bar 2580 in a second direction. Rotation of the
knife bar 2580 in the second direction results in the rotation of the
closure drive nut 2560 in a second direction. As the closure drive nut
2560 rotates in the second direction, the closure tube 2550 moves in the
proximal direction "PD". As the closure tube 2550 moves in the proximal
direction "PD", the tab 2527 on the anvil 2524 interfaces with the
opening 2555 in the closure tube 2550 and causes the anvil 2524 to pivot
to the open position. In addition or in alternative embodiments, a spring
(not shown) may be employed to pivot the anvil 2354 to the open position
when the closure tube 2550 has been returned to the starting position
(FIG. 40). The opened surgical end effector 2512 may then be manipulated
by the robotic system 1000 to position the target tissue between the open
anvil 2524 and the surgical staple cartridge 2534. Thereafter, the
surgeon may initiate the closure process by activating the robotic
control system 1000 to apply the second rotary output motion to the
closure drive gear 2622 which, as was described above, ultimately results
in the rotation of the closure drive nut 2382 in the second direction
which results in the axial travel of the closure tube 2250 in the distal
direction "DD". As the closure tube 2550 moves in the distal direction,
it contacts a portion of the anvil 2524 and causes the anvil 2524 to
pivot to the closed position to clamp the target tissue between the anvil
2524 and the staple cartridge 2534. Once the robotic controller 1001
determines that the anvil 2524 has been pivoted to the closed position by
corresponding sensor(s) in the end effector 2512 that are in
communication therewith, the robotic controller 1001 discontinues the
application of the second rotary output motion to the closure drive gear
2622. The robotic controller 1001 may also provide the surgeon with an
indication that the anvil 2524 has been fully closed. The surgeon may
then initiate the firing procedure. In alternative embodiments, the
firing procedure may be automatically initiated by the robotic controller
1001.

[0213] After the robotic controller 1001 has determined that the anvil
2524 is in the closed position, the robotic controller 1001 then applies
the third rotary output motion to the rotary drive gear 2652 which
results in the axial movement of the drive shaft assembly 2640 and knife
bar 2580 in the distal direction "DD". As the cutting instrument 2532
moves distally through the surgical staple cartridge 2534, the tissue
clamped therein is severed. As the sled portion (not shown) is driven
distally, it causes the staples within the surgical staple cartridge 2534
to be driven through the severed tissue into forming contact with the
anvil 2524. Once the robotic controller 1001 has determined that the
cutting instrument 2532 has reached the end position within the surgical
staple cartridge 2534 by means of sensor(s) in the surgical end effector
2512 that are in communication with the robotic controller 1001, the
robotic controller 1001 discontinues the application of the second rotary
output motion to the rotary drive gear 2652. Thereafter, the robotic
controller 1001 applies the secondary rotary control motion to the rotary
drive gear 2652 which ultimately results in the axial travel of the
cutting instrument 2532 and sled portion in the proximal direction "PD"
to the starting position. Once the robotic controller 1001 has determined
that the cutting instrument 2524 has reached the starting position by
means of sensor(s) in the end effector 2512 that are in communication
with the robotic controller 1001, the robotic controller 1001
discontinues the application of the secondary rotary output motion to the
rotary drive gear 2652. Thereafter, the robotic controller 1001 may apply
the secondary rotary output motion to the closure drive gear 2622 which
results in the rotation of the knife bar 2580 in a secondary direction.
Rotation of the knife bar 2580 in the secondary direction results in the
rotation of the closure drive nut 2560 in a secondary direction. As the
closure drive nut 2560 rotates in the secondary direction, the closure
tube 2550 moves in the proximal direction "PD" to the open position.

[0214] FIGS. 44-49B illustrate yet another surgical tool 2700 that may be
effectively employed in connection with the robotic system 1000. In
various forms, the surgical tool 2700 includes a surgical end effector
2712 that includes a "first portion" in the form of an elongated channel
2722 and a "second movable portion" in on form comprising a pivotally
translatable clamping member, such as an anvil 2724, which are maintained
at a spacing that assures effective stapling and severing of tissue
clamped in the surgical end effector 2712. As shown in the illustrated
embodiment, the surgical end effector 2712 may include, in addition to
the previously-mentioned channel 2722 and anvil 2724, a "third movable
portion" in the form of a cutting instrument 2732, a sled (not shown),
and a surgical staple cartridge 2734 that is removably seated in the
elongated channel 2722. The cutting instrument 2732 may be, for example,
a knife. The anvil 2724 may be pivotably opened and closed at a pivot
point 2725 connected to the proximal end of the elongated channel 2722.
The anvil 2724 may also include a tab 2727 at its proximal end that
interfaces with a component of the mechanical closure system (described
further below) to open and close the anvil 2724. When actuated, the knife
2732 and sled to travel longitudinally along the elongated channel 2722,
thereby cutting tissue clamped within the surgical end effector 2712. The
movement of the sled along the elongated channel 2722 causes the staples
of the surgical staple cartridge 2734 to be driven through the severed
tissue and against the closed anvil 2724, which turns the staples to
fasten the severed tissue. In one form, the elongated channel 2722 and
the anvil 2724 may be made of an electrically conductive material (such
as metal) so that they may serve as part of the antenna that communicates
with sensor(s) in the surgical end effector, as described above. The
surgical staple cartridge 2734 could be made of a nonconductive material
(such as plastic) and the sensor may be connected to or disposed in the
surgical staple cartridge 2734, as described above.

[0215] It should be noted that although the embodiments of the surgical
tool 2500 described herein employ a surgical end effector 2712 that
staples the severed tissue, in other embodiments different techniques for
fastening or sealing the severed tissue may be used. For example, end
effectors that use RF energy or adhesives to fasten the severed tissue
may also be used. U.S. Pat. No. 5,709,680, entitled "Electrosurgical
Hemostatic Device" to Yates et al., and U.S. Pat. No. 5,688,270, entitled
"Electrosurgical Hemostatic Device With Recessed And/Or Offset
Electrodes" to Yates et al., which are incorporated herein by reference,
discloses cutting instruments that use RF energy to fasten the severed
tissue. U.S. patent application Ser. No. 11/267,811 to Morgan et al. and
U.S. patent application Ser. No. 11/267,363 to Shelton et al., which are
also incorporated herein by reference, disclose cutting instruments that
use adhesives to fasten the severed tissue. Accordingly, although the
description herein refers to cutting/stapling operations and the like, it
should be recognized that this is an exemplary embodiment and is not
meant to be limiting. Other tissue-fastening techniques may also be used.

[0216] In the illustrated embodiment, the elongated channel 2722 of the
surgical end effector 2712 is coupled to an elongated shaft assembly 2708
that is coupled to a tool mounting portion 2900. Although not shown, the
elongated shaft assembly 2708 may include an articulation joint to permit
the surgical end effector 2712 to be selectively articulated about an
axis that is substantially transverse to the tool axis LT-LT. In at least
one embodiment, the elongated shaft assembly 2708 comprises a hollow
spine tube 2740 that is non-movably coupled to a tool mounting plate 2902
of the tool mounting portion 2900. As can be seen in FIGS. 45 and 46, the
proximal end 2723 of the elongated channel 2722 comprises a hollow
tubular structure that is attached to the spine tube 2740 by means of a
mounting collar 2790. A cross-sectional view of the mounting collar 2790
is shown in FIG. 47. In various embodiments, the mounting collar 2790 has
a proximal flanged end 2791 that is configured for attachment to the
distal end of the spine tube 2740. In at least one embodiment, for
example, the proximal flanged end 2791 of the mounting collar 2790 is
welded or glued to the distal end of the spine tube 2740. As can be
further seen in FIGS. 45 and 46, the mounting collar 2790 further has a
mounting hub portion 2792 that is sized to receive the proximal end 2723
of the elongated channel 2722 thereon. The proximal end 2723 of the
elongated channel 2722 is non-movably attached to the mounting hub
portion 2792 by, for example, welding, adhesive, etc.

[0217] As can be further seen in FIGS. 45 and 46, the surgical tool 2700
further includes an axially movable actuation member in the form of a
closure tube 2750 that is constrained to move axially relative to the
elongated channel 2722. The closure tube 2750 has a proximal end 2752
that has an internal thread 2754 formed therein that is in threaded
engagement with a rotatably movable portion in the form of a closure
drive nut 2760. More specifically, the closure drive nut 2760 has a
proximal end portion 2762 that is rotatably supported relative to the
elongated channel 2722 and the spine tube 2740. For assembly purposes,
the proximal end portion 2762 is threadably attached to a retention ring
2770. The retention ring 2770 is received in a groove 2729 formed between
a shoulder 2727 on the proximal end 2723 of the channel 2722 and the
mounting hub 2729 of the mounting collar 2790. Such arrangement serves to
rotatably support the closure drive nut 2760 within the channel 2722.
Rotation of the closure drive nut 2760 will cause the closure tube 2750
to move axially as represented by arrow "D" in FIG. 45.

[0218] Extending through the spine tube 2740, the mounting collar 2790,
and the closure drive nut 2760 is a drive member, which in at least one
embodiment, comprises a knife bar 2780 that has a distal end portion 2782
that is coupled to the cutting instrument 2732. As can be seen in FIGS.
45 and 46, the mounting collar 2790 has a passage 2793 therethrough for
permitting the knife bar 2780 to slidably pass therethrough. Similarly,
the closure drive nut 2760 has a slot 2764 therein through which the
knife bar 2780 can slidably extend. Such arrangement permits the knife
bar 2780 to move axially relative to the closure drive nut 2760.

[0219] Actuation of the anvil 2724 is controlled by a rotary driven
closure shaft 2800. As can be seen in FIGS. 45 and 46, a distal end
portion 2802 of the closure drive shaft 2800 extends through a passage
2794 in the mounting collar 2790 and a closure gear 2804 is attached
thereto. The closure gear 2804 is configured for driving engagement with
the inner surface 2761 of the closure drive nut 2760. Thus, rotation of
the closure shaft 2800 will also result in the rotation of the closure
drive nut 2760. The axial direction in which the closure tube 2750 moves
ultimately depends upon the direction in which the closure shaft 2800 and
the closure drive nut 2760 are rotated. For example, in response to one
rotary closure motion received from the robotic system 1000, the closure
tube 2750 will be driven in the distal direction "DD". As the closure
tube 2750 is driven distally, the opening 2745 will engage the tab 2727
on the anvil 2724 and cause the anvil 2724 to pivot to a closed position.
Upon application of an opening rotary motion from the robotic system
1000, the closure tube 2750 will be driven in the proximal direction "PD"
and pivot the anvil 2724 to the open position. In various embodiments, a
spring (not shown) may be employed to bias the anvil 2724 to the open
position (FIG. 45).

[0220] In use, it may be desirable to rotate the surgical end effector
2712 about the longitudinal tool axis LT-LT. In at least one embodiment,
the tool mounting portion 2900 is configured to receive a corresponding
first rotary output motion from the robotic system 1000 for rotating the
elongated shaft assembly 2708 about the tool axis LT-LT. As can be seen
in FIG. 49, a proximal end 2742 of the hollow spine tube 2740 is
rotatably supported within a cradle arrangement 2903 and a bearing
assembly 2904 that are attached to a tool mounting plate 2902 of the tool
mounting portion 2900. A rotation gear 2744 is formed on or attached to
the proximal end 2742 of the spine tube 2740 for meshing engagement with
a rotation drive assembly 2910 that is operably supported on the tool
mounting plate 2902. In at least one embodiment, a rotation drive gear
2912 is coupled to a corresponding first one of the driven discs or
elements 1304 on the adapter side of the tool mounting plate 2602 when
the tool mounting portion 2600 is coupled to the tool holder 1270. See
FIGS. 22 and 49. The rotation drive assembly 2910 further comprises a
rotary driven gear 2914 that is rotatably supported on the tool mounting
plate 2902 in meshing engagement with the rotation gear 2744 and the
rotation drive gear 2912. Application of a first rotary control motion
from the robotic system 1000 through the tool holder 1270 and the adapter
1240 to the corresponding driven element 1304 will thereby cause rotation
of the rotation drive gear 2912 by virtue of being operably coupled
thereto. Rotation of the rotation drive gear 2912 ultimately results in
the rotation of the elongated shaft assembly 2708 (and the end effector
2712) about the longitudinal tool axis LT-LT (primary rotary motion).

[0221] Closure of the anvil 2724 relative to the staple cartridge 2734 is
accomplished by axially moving the closure tube 2750 in the distal
direction "DD". Axial movement of the closure tube 2750 in the distal
direction "DD" is accomplished by applying a rotary control motion to the
closure drive nut 2760. In various embodiments, the closure drive nut
2760 is rotated by applying a rotary output motion to the closure drive
shaft 2800. As can be seen in FIG. 49, a proximal end portion 2806 of the
closure drive shaft 2800 has a driven gear 2808 thereon that is in
meshing engagement with a closure drive assembly 2920. In various
embodiments, the closure drive system 2920 includes a closure drive gear
2922 that is coupled to a corresponding second one of the driven
rotational bodies or elements 1304 on the adapter side of the tool
mounting plate 2462 when the tool mounting portion 2900 is coupled to the
tool holder 1270. See FIGS. 22 and 49. The closure drive gear 2922 is
supported in meshing engagement with a closure gear train, generally
depicted as 2923. In at least one form, the closure gear rain 2923
comprises a first driven closure gear 2924 that is rotatably supported on
the tool mounting plate 2902. The first closure driven gear 2924 is
attached to a second closure driven gear 2926 by a drive shaft 2928. The
second closure driven gear 2926 is in meshing engagement with a planetary
gear assembly 2930. In various embodiments, the planetary gear assembly
2930 includes a driven planetary closure gear 2932 that is rotatably
supported within the bearing assembly 2904 that is mounted on tool
mounting plate 2902. As can be seen in FIGS. 49 and 49B, the proximal end
portion 2806 of the closure drive shaft 2800 is rotatably supported
within the proximal end portion 2742 of the spine tube 2740 such that the
driven gear 2808 is in meshing engagement with central gear teeth 2934
formed on the planetary gear 2932. As can also be seen in FIG. 49A, two
additional support gears 2936 are attached to or rotatably supported
relative to the proximal end portion 2742 of the spine tube 2740 to
provide bearing support thereto. Such arrangement with the planetary gear
assembly 2930 serves to accommodate rotation of the spine shaft 2740 by
the rotation drive assembly 2910 while permitting the closure driven gear
2808 to remain in meshing engagement with the closure drive system 2920.
In addition, rotation of the closure drive gear 2922 in a first direction
will ultimately result in the rotation of the closure drive shaft 2800
and closure drive nut 2760 which will ultimately result in the closure of
the anvil 2724 as described above. Conversely, rotation of the closure
drive gear 2922 in a second opposite direction will ultimately result in
the rotation of the closure drive nut 2760 in an opposite direction which
results in the opening of the anvil 2724.

[0222] As can be seen in FIG. 49, the proximal end 2784 of the knife bar
2780 has a threaded shaft portion 2786 attached thereto which is in
driving engagement with a knife drive assembly 2940. In various
embodiments, the threaded shaft portion 2786 is rotatably supported by a
bearing 2906 attached to the tool mounting plate 2902. Such arrangement
permits the threaded shaft portion 2786 to rotate and move axially
relative to the tool mounting plate 2902. The knife bar 2780 is axially
advanced in the distal and proximal directions by the knife drive
assembly 2940. One form of the knife drive assembly 2940 comprises a
rotary drive gear 2942 that is coupled to a corresponding third one of
the rotatable bodies, driven discs or elements 1304 on the adapter side
of the tool mounting plate 2902 when the tool mounting portion 2900 is
coupled to the tool holder 1270. See FIGS. 22 and 49. The rotary drive
gear 2942 is in meshing engagement with a knife gear train, generally
depicted as 2943. In various embodiments, the knife gear train 2943
comprises a first rotary driven gear assembly 2944 that is rotatably
supported on the tool mounting plate 2902. The first rotary driven gear
assembly 2944 is in meshing engagement with a third rotary driven gear
assembly 2946 that is rotatably supported on the tool mounting plate 2902
and which is in meshing engagement with a fourth rotary driven gear
assembly 2948 that is in meshing engagement with the threaded portion
2786 of the knife bar 2780. Rotation of the rotary drive gear 2942 in one
direction will result in the axial advancement of the knife bar 2780 in
the distal direction "DD". Conversely, rotation of the rotary drive gear
2942 in an opposite direction will cause the knife bar 2780 to move in
the proximal direction. Tool 2700 may otherwise be used as described
above.

[0223] FIGS. 50 and 51 illustrate a surgical tool embodiment 2700' that is
substantially identical to tool 2700 that was described in detail above.
However tool 2700' includes a pressure sensor 2950 that is configured to
provide feedback to the robotic controller 1001 concerning the amount of
clamping pressure experienced by the anvil 2724. In various embodiments,
for example, the pressure sensor may comprise a spring biased contact
switch. For a continuous signal, it would use either a cantilever beam
with a strain gage on it or a dome button top with a strain gage on the
inside. Another version may comprise an off switch that contacts only at
a known desired load. Such arrangement would include a dome on the based
wherein the dome is one electrical pole and the base is the other
electrical pole. Such arrangement permits the robotic controller 1001 to
adjust the amount of clamping pressure being applied to the tissue within
the surgical end effector 2712 by adjusting the amount of closing
pressure applied to the anvil 2724. Those of ordinary skill in the art
will understand that such pressure sensor arrangement may be effectively
employed with several of the surgical tool embodiments described herein
as well as their equivalent structures.

[0224] FIG. 52 illustrates a portion of another surgical tool 3000 that
may be effectively used in connection with a robotic system 1000. The
surgical tool 3003 employs on-board motor(s) for powering various
components of a surgical end effector cutting instrument. In at least one
non-limiting embodiment for example, the surgical tool 3000 includes a
surgical end effector in the form of an endocutter (not shown) that has
an anvil (not shown) and surgical staple cartridge arrangement (not
shown) of the types and constructions described above. The surgical tool
3000 also includes an elongated shaft (not shown) and anvil closure
arrangement (not shown) of the types described above. Thus, this portion
of the Detailed Description will not repeat the description of those
components beyond that which is necessary to appreciate the unique and
novel attributes of the various embodiments of surgical tool 3000.

[0225] In the depicted embodiment, the end effector includes a cutting
instrument 3002 that is coupled to a knife bar 3003. As can be seen in
FIG. 52, the surgical tool 3000 includes a tool mounting portion 3010
that includes a tool mounting plate 3012 that is configured to mountingly
interface with the adaptor portion 1240' which is coupled to the robotic
system 1000 in the various manners described above. The tool mounting
portion 3010 is configured to operably support a transmission arrangement
3013 thereon. In at least one embodiment, the adaptor portion 1240' may
be identical to the adaptor portion 1240 described in detail above
without the powered rotation bodies and disc members employed by adapter
1240. In other embodiments, the adaptor portion 1240' may be identical to
adaptor portion 1240. Still other modifications which are considered to
be within the spirit and scope of the various forms of the present
invention may employ one or more of the mechanical motions (i.e., rotary
motion(s)) from the tool holder portion 1270 (as described hereinabove)
to power/actuate the transmission arrangement 3013 while also employing
one or more motors within the tool mounting portion 3010 to power one or
more other components of the surgical end effector. In addition, while
the end effector of the depicted embodiment comprises an endocutter,
those of ordinary skill in the art will understand that the unique and
novel attributes of the depicted embodiment may be effectively employed
in connection with other types of surgical end effectors without
departing from the spirit and scope of various forms of the present
invention.

[0226] In various embodiments, the tool mounting plate 3012 is configured
to at least house a first firing motor 3011 for supplying firing and
retraction motions to the knife bar 3003 which is coupled to or otherwise
operably interfaces with the cutting instrument 3002. The tool mounting
plate 3012 has an array of electrical connecting pins 3014 which are
configured to interface with the slots 1258 (FIG. 21) in the adapter
1240'. Such arrangement permits the controller 1001 of the robotic system
1000 to provide control signals to the electronic control circuit 3020 of
the surgical tool 3000. While the interface is described herein with
reference to mechanical, electrical, and magnetic coupling elements, it
should be understood that a wide variety of telemetry modalities might be
used, including infrared, inductive coupling, or the like.

[0227] Control circuit 3020 is shown in schematic form in FIG. 52. In one
form or embodiment, the control circuit 3020 includes a power supply in
the form of a battery 3022 that is coupled to an on-off solenoid powered
switch 3024. Control circuit 3020 further includes an on/off firing
solenoid 3026 that is coupled to a double pole switch 3028 for
controlling the rotational direction of the motor 3011. Thus, when the
controller 1001 of the robotic system 1000 supplies an appropriate
control signal, switch 3024 will permit battery 3022 to supply power to
the double pole switch 3028. The controller 1001 of the robotic system
1000 will also supply an appropriate signal to the double pole switch
3028 to supply power to the motor 3011. When it is desired to fire the
surgical end effector (i.e., drive the cutting instrument 3002 distally
through tissue clamped in the surgical end effector, the double pole
switch 3028 will be in a first position. When it is desired to retract
the cutting instrument 3002 to the starting position, the double pole
switch 3028 will be moved to the second position by the controller 1001.

[0228] Various embodiments of the surgical tool 3000 also employ a gear
box 3030 that is sized, in cooperation with a firing gear train 3031
that, in at least one non-limiting embodiment, comprises a firing drive
gear 3032 that is in meshing engagement with a firing driven gear 3034
for generating a desired amount of driving force necessary to drive the
cutting instrument 3002 through tissue and to drive and form staples in
the various manners described herein. In the embodiment depicted in FIG.
52, the driven gear 3034 is coupled to a screw shaft 3036 that is in
threaded engagement with a screw nut arrangement 3038 that is constrained
to move axially (represented by arrow "D"). The screw nut arrangement
3038 is attached to the firing bar 3003. Thus, by rotating the screw
shaft 3036 in a first direction, the cutting instrument 3002 is driven in
the distal direction "DD" and rotating the screw shaft in an opposite
second direction, the cutting instrument 3002 may be retracted in the
proximal direction "PD".

[0229] FIG. 53 illustrates a portion of another surgical tool 3000' that
is substantially identical to tool 3000 described above, except that the
driven gear 3034 is attached to a drive shaft 3040. The drive shaft 3040
is attached to a second driver gear 3042 that is in meshing engagement
with a third driven gear 3044 that is in meshing engagement with a screw
3046 coupled to the firing bar 3003.

[0230]FIG. 54 illustrates another surgical tool 3200 that may be
effectively used in connection with a robotic system 1000. In this
embodiment, the surgical tool 3200 includes a surgical end effector 3212
that in one non-limiting form, comprises a component portion that is
selectively movable between first and second positions relative to at
least one other end effector component portion. As will be discussed in
further detail below, the surgical tool 3200 employs on-board motors for
powering various components of a transmission arrangement 3305. The
surgical end effector 3212 includes an elongated channel 3222 that
operably supports a surgical staple cartridge 3234. The elongated channel
3222 has a proximal end 3223 that slidably extends into a hollow
elongated shaft assembly 3208 that is coupled to a tool mounting portion
3300. In addition, the surgical end effector 3212 includes an anvil 3224
that is pivotally coupled to the elongated channel 3222 by a pair of
trunnions 3225 that are received within corresponding openings 3229 in
the elongated channel 3222. A distal end portion 3209 of the shaft
assembly 3208 includes an opening 3245 into which a tab 3227 on the anvil
3224 is inserted in order to open the anvil 3224 as the elongated channel
3222 is moved axially in the proximal direction "PD" relative to the
distal end portion 3209 of the shaft assembly 3208. In various
embodiments, a spring (not shown) may be employed to bias the anvil 3224
to the open position.

[0231] As indicated above, the surgical tool 3200 includes a tool mounting
portion 3300 that includes a tool mounting plate 3302 that is configured
to operably support the transmission arrangement 3305 and to mountingly
interface with the adaptor portion 1240' which is coupled to the robotic
system 1000 in the various manners described above. In at least one
embodiment, the adaptor portion 1240' may be identical to the adaptor
portion 1240 described in detail above without the powered disc members
employed by adapter 1240. In other embodiments, the adaptor portion 1240'
may be identical to adaptor portion 1240. However, in such embodiments,
because the various components of the surgical end effector 3212 are all
powered by motor(s) in the tool mounting portion 3300, the surgical tool
3200 will not employ or require any of the mechanical (i.e.,
non-electrical) actuation motions from the tool holder portion 1270 to
power the surgical end effector 3200 components. Still other
modifications which are considered to be within the spirit and scope of
the various forms of the present invention may employ one or more of the
mechanical motions from the tool holder portion 1270 (as described
hereinabove) to power/actuate one or more of the surgical end effector
components while also employing one or more motors within the tool
mounting portion to power one or more other components of the surgical
end effector.

[0232] In various embodiments, the tool mounting plate 3302 is configured
to support a first firing motor 3310 for supplying firing and retraction
motions to the transmission arrangement 3305 to drive a knife bar 3335
that is coupled to a cutting instrument 3332 of the type described above.
As can be seen in FIG. 54, the tool mounting plate 3212 has an array of
electrical connecting pins 3014 which are configured to interface with
the slots 1258 (FIG. 21) in the adapter 1240'. Such arrangement permits
the controller 1001 of the robotic system 1000 to provide control signals
to the electronic control circuits 3320, 3340 of the surgical tool 3200.
While the interface is described herein with reference to mechanical,
electrical, and magnetic coupling elements, it should be understood that
a wide variety of telemetry modalities might be used, including infrared,
inductive coupling, or the like.

[0233] In one form or embodiment, the first control circuit 3320 includes
a first power supply in the form of a first battery 3322 that is coupled
to a first on-off solenoid powered switch 3324. The first firing control
circuit 3320 further includes a first on/off firing solenoid 3326 that is
coupled to a first double pole switch 3328 for controlling the rotational
direction of the first firing motor 3310. Thus, when the robotic
controller 1001 supplies an appropriate control signal, the first switch
3324 will permit the first battery 3322 to supply power to the first
double pole switch 3328. The robotic controller 1001 will also supply an
appropriate signal to the first double pole switch 3328 to supply power
to the first firing motor 3310. When it is desired to fire the surgical
end effector (i.e., drive the cutting instrument 3232 distally through
tissue clamped in the surgical end effector 3212, the first switch 3328
will be positioned in a first position by the robotic controller 1001.
When it is desired to retract the cutting instrument 3232 to the starting
position, the robotic controller 1001 will send the appropriate control
signal to move the first switch 3328 to the second position.

[0234] Various embodiments of the surgical tool 3200 also employ a first
gear box 3330 that is sized, in cooperation with a firing drive gear 3332
coupled thereto that operably interfaces with a firing gear train 3333.
In at least one non-limiting embodiment, the firing gear train 333
comprises a firing driven gear 3334 that is in meshing engagement with
drive gear 3332, for generating a desired amount of driving force
necessary to drive the cutting instrument 3232 through tissue and to
drive and form staples in the various manners described herein. In the
embodiment depicted in FIG. 54, the driven gear 3334 is coupled to a
drive shaft 3335 that has a second driven gear 3336 coupled thereto. The
second driven gear 3336 is supported in meshing engagement with a third
driven gear 3337 that is in meshing engagement with a fourth driven gear
3338. The fourth driven gear 3338 is in meshing engagement with a
threaded proximal portion 3339 of the knife bar 3235 that is constrained
to move axially. Thus, by rotating the drive shaft 3335 in a first
direction, the cutting instrument 3232 is driven in the distal direction
"DD" and rotating the drive shaft 3335 in an opposite second direction,
the cutting instrument 3232 may be retracted in the proximal direction
"PD".

[0235] As indicated above, the opening and closing of the anvil 3224 is
controlled by axially moving the elongated channel 3222 relative to the
elongated shaft assembly 3208. The axial movement of the elongated
channel 3222 is controlled by a closure control system 3339. In various
embodiments, the closure control system 3339 includes a closure shaft
3340 which has a hollow threaded end portion 3341 that threadably engages
a threaded closure rod 3342. The threaded end portion 3341 is rotatably
supported in a spine shaft 3343 that operably interfaces with the tool
mounting portion 3300 and extends through a portion of the shaft assembly
3208 as shown. The closure system 3339 further comprises a closure
control circuit 3350 that includes a second power supply in the form of a
second battery 3352 that is coupled to a second on-off solenoid powered
switch 3354. Closure control circuit 3350 further includes a second
on/off firing solenoid 3356 that is coupled to a second double pole
switch 3358 for controlling the rotation of a second closure motor 3360.
Thus, when the robotic controller 1001 supplies an appropriate control
signal, the second switch 3354 will permit the second battery 3352 to
supply power to the second double pole switch 3354. The robotic
controller 1001 will also supply an appropriate signal to the second
double pole switch 3358 to supply power to the second motor 3360. When it
is desired to close the anvil 3224, the second switch 3348 will be in a
first position. When it is desired to open the anvil 3224, the second
switch 3348 will be moved to a second position.

[0236] Various embodiments of tool mounting portion 3300 also employ a
second gear box 3362 that is coupled to a closure drive gear 3364. The
closure drive gear 3364 is in meshing engagement with a closure gear
train 3363. In various non-limiting forms, the closure gear train 3363
includes a closure driven gear 3365 that is attached to a closure drive
shaft 3366. Also attached to the closure drive shaft 3366 is a closure
drive gear 3367 that is in meshing engagement with a closure shaft gear
3360 attached to the closure shaft 3340. FIG. 54 depicts the end effector
3212 in the open position. As indicated above, when the threaded closure
rod 3342 is in the position depicted in FIG. 54, a spring (not shown)
biases the anvil 3224 to the open position. When it is desired to close
the anvil 3224, the robotic controller 1001 will activate the second
motor 3360 to rotate the closure shaft 3340 to draw the threaded closure
rod 3342 and the channel 3222 in the proximal direction `PD`. As the
anvil 3224 contacts the distal end portion 3209 of the shaft 3208, the
anvil 3224 is pivoted to the closed position.

[0237] A method of operating the surgical tool 3200 will now be described.
Once the tool mounting portion 3302 has be operably coupled to the tool
holder 1270 of the robotic system 1000, the robotic system 1000 can
orient the end effector 3212 in position adjacent the target tissue to be
cut and stapled. If the anvil 3224 is not already in the open position,
the robotic controller 1001 may activate the second closure motor 3360 to
drive the channel 3222 in the distal direction to the position depicted
in FIG. 54. Once the robotic controller 1001 determines that the surgical
end effector 3212 is in the open position by sensor(s) in the and
effector and/or the tool mounting portion 3300, the robotic controller
1001 may provide the surgeon with a signal to inform the surgeon that the
anvil 3224 may then be closed. Once the target tissue is positioned
between the open anvil 3224 and the surgical staple cartridge 3234, the
surgeon may then commence the closure process by activating the robotic
controller 1001 to apply a closure control signal to the second closure
motor 3360. The second closure motor 3360 applies a rotary motion to the
closure shaft 3340 to draw the channel 3222 in the proximal direction
"PD" until the anvil 3224 has been pivoted to the closed position. Once
the robotic controller 1001 determines that the anvil 3224 has been moved
to the closed position by sensor(s) in the surgical end effector 3212
and/or in the tool mounting portion 3300 that are in communication with
the robotic control system, the motor 3360 may be deactivated.
Thereafter, the firing process may be commenced either manually by the
surgeon activating a trigger, button, etc. on the controller 1001 or the
controller 1001 may automatically commence the firing process.

[0238] To commence the firing process, the robotic controller 1001
activates the firing motor 3310 to drive the firing bar 3235 and the
cutting instrument 3232 in the distal direction "DD". Once robotic
controller 1001 has determined that the cutting instrument 3232 has moved
to the ending position within the surgical staple cartridge 3234 by means
of sensors in the surgical end effector 3212 and/or the motor drive
portion 3300, the robotic controller 1001 may provide the surgeon with an
indication signal. Thereafter the surgeon may manually activate the first
motor 3310 to retract the cutting instrument 3232 to the starting
position or the robotic controller 1001 may automatically activate the
first motor 3310 to retract the cutting element 3232.

[0239] The embodiment depicted in FIG. 54 does not include an articulation
joint. FIGS. 55 and 56 illustrate surgical tools 3200' and 3200'' that
have end effectors 3212', 3212'', respectively that may be employed with
an elongated shaft embodiment that has an articulation joint of the
various types disclosed herein. For example, as can be seen in FIG. 55, a
threaded closure shaft 3342 is coupled to the proximal end 3223 of the
elongated channel 3222 by a flexible cable or other flexible member 3345.
The location of an articulation joint (not shown) within the elongated
shaft assembly 3208 will coincide with the flexible member 3345 to enable
the flexible member 3345 to accommodate such articulation. In addition,
in the above-described embodiment, the flexible member 33345 is rotatably
affixed to the proximal end portion 3223 of the elongated channel 3222 to
enable the flexible member 3345 to rotate relative thereto to prevent the
flexible member 3229 from "winding up" relative to the channel 3222.
Although not shown, the cutting element may be driven in one of the above
described manners by a knife bar that can also accommodate articulation
of the elongated shaft assembly. FIG. 56 depicts a surgical end effector
3212'' that is substantially identical to the surgical end effector 3212
described above, except that the threaded closure rod 3342 is attached to
a closure nut 3347 that is constrained to only move axially within the
elongated shaft assembly 3208. The flexible member 3345 is attached to
the closure nut 3347. Such arrangement also prevents the threaded closure
rod 3342 from winding-up the flexible member 3345. A flexible knife bar
3235' may be employed to facilitate articulation of the surgical end
effector 3212''.

[0240] The surgical tools 3200, 3200', and 3200'' described above may also
employ anyone of the cutting instrument embodiments described herein. As
described above, the anvil of each of the end effectors of these tools is
closed by drawing the elongated channel into contact with the distal end
of the elongated shaft assembly. Thus, once the target tissue has been
located between the staple cartridge 3234 and the anvil 3224, the robotic
controller 1001 can start to draw the channel 3222 inward into the shaft
assembly 3208. In various embodiments, however, to prevent the end
effector 3212, 3212', 3212'' from moving the target tissue with the end
effector during this closing process, the controller 1001 may
simultaneously move the tool holder and ultimately the tool such to
compensate for the movement of the elongated channel 3222 so that, in
effect, the target tissue is clamped between the anvil and the elongated
channel without being otherwise moved.

[0241] FIGS. 57-59 depict another surgical tool embodiment 3201 that is
substantially identical to surgical tool 3200'' described above, except
for the differences discussed below. In this embodiment, the threaded
closure rod 3342' has variable pitched grooves. More specifically, as can
be seen in FIG. 58, the closure rod 3342' has a distal groove section
3380 and a proximal groove section 3382. The distal and proximal groove
sections 3380, 3382 are configured for engagement with a lug 3390
supported within the hollow threaded end portion 3341'. As can be seen in
FIG. 58, the distal groove section 3380 has a finer pitch than the groove
section 3382. Thus, such variable pitch arrangement permits the elongated
channel 3222 to be drawn into the shaft 3208 at a first speed or rate by
virtue of the engagement between the lug 3390 and the proximal groove
segment 3382. When the lug 3390 engages the distal groove segment, the
channel 3222 will be drawn into the shaft 3208 at a second speed or rate.
Because the proximal groove segment 3382 is coarser than the distal
groove segment 3380, the first speed will be greater than the second
speed. Such arrangement serves to speed up the initial closing of the end
effector for tissue manipulation and then after the tissue has been
properly positioned therein, generate the amount of closure forces to
properly clamp the tissue for cutting and sealing. Thus, the anvil 3234
initially closes fast with a lower force and then applies a higher
closing force as the anvil closes more slowly.

[0242] The surgical end effector opening and closing motions are employed
to enable the user to use the end effector to grasp and manipulate tissue
prior to fully clamping it in the desired location for cutting and
sealing. The user may, for example, open and close the surgical end
effector numerous times during this process to orient the end effector in
a proper position which enables the tissue to be held in a desired
location. Thus, in at least some embodiments, to produce the high loading
for firing, the fine thread may require as many as 5-10 full rotations to
generate the necessary load. In some cases, for example, this action
could take as long as 2-5 seconds. If it also took an equally long time
to open and close the end effector each time during the
positioning/tissue manipulation process, just positioning the end
effector may take an undesirably long time. If that happens, it is
possible that a user may abandon such use of the end effector for use of
a conventional grasper device. Use of graspers, etc. may undesirably
increase the costs associated with completing the surgical procedure.

[0243] The above-described embodiments employ a battery or batteries to
power the motors used to drive the end effector components. Activation of
the motors is controlled by the robotic system 1000. In alternative
embodiments, the power supply may comprise alternating current "AC" that
is supplied to the motors by the robotic system 1000. That is, the AC
power would be supplied from the system powering the robotic system 1000
through the tool holder and adapter. In still other embodiments, a power
cord or tether may be attached to the tool mounting portion 3300 to
supply the requisite power from a separate source of alternating or
direct current.

[0244] In use, the controller 1001 may apply an initial rotary motion to
the closure shaft 3340 (FIG. 54) to draw the elongated channel 3222
axially inwardly into the elongated shaft assembly 3208 and move the
anvil from a first position to an intermediate position at a first rate
that corresponds with the point wherein the distal groove section 3380
transitions to the proximal groove section 3382. Further application of
rotary motion to the closure shaft 3340 will cause the anvil to move from
the intermediate position to the closed position relative to the surgical
staple cartridge. When in the closed position, the tissue to be cut and
stapled is properly clamped between the anvil and the surgical staple
cartridge.

[0245] FIGS. 60-64 illustrate another surgical tool embodiment 3400 of the
present invention. This embodiment includes an elongated shaft assembly
3408 that extends from a tool mounting portion 3500. The elongated shaft
assembly 3408 includes a rotatable proximal closure tube segment 3410
that is rotatably journaled on a proximal spine member 3420 that is
rigidly coupled to a tool mounting plate 3502 of the tool mounting
portion 3500. The proximal spine member 3420 has a distal end 3422 that
is coupled to an elongated channel portion 3522 of a surgical end
effector 3412. For example, in at least one embodiment, the elongated
channel portion 3522 has a distal end portion 3523 that "hookingly
engages" the distal end 3422 of the spine member 3420. The elongated
channel 3522 is configured to support a surgical staple cartridge 3534
therein. This embodiment may employ one of the various cutting instrument
embodiments disclosed herein to sever tissue that is clamped in the
surgical end effector 3412 and fire the staples in the staple cartridge
3534 into the severed tissue.

[0246] Surgical end effector 3412 has an anvil 3524 that is pivotally
coupled to the elongated channel 3522 by a pair of trunnions 3525 that
are received in corresponding openings 3529 in the elongated channel
3522. The anvil 3524 is moved between the open (FIG. 60) and closed
positions (FIGS. 61-63) by a distal closure tube segment 3430. A distal
end portion 3432 of the distal closure tube segment 3430 includes an
opening 3445 into which a tab 3527 on the anvil 3524 is inserted in order
to open and close the anvil 3524 as the distal closure tube segment 3430
moves axially relative thereto. In various embodiments, the opening 3445
is shaped such that as the closure tube segment 3430 is moved in the
proximal direction, the closure tube segment 3430 causes the anvil 3524
to pivot to an open position. In addition or in the alternative, a spring
(not shown) may be employed to bias the anvil 3524 to the open position.

[0247] As can be seen in FIGS. 60-63, the distal closure tube segment 3430
includes a lug 3442 that extends from its distal end 3440 into threaded
engagement with a variable pitch groove/thread 3414 formed in the distal
end 3412 of the rotatable proximal closure tube segment 3410. The
variable pitch groove/thread 3414 has a distal section 3416 and a
proximal section 3418. The pitch of the distal groove/thread section 3416
is finer than the pitch of the proximal groove/thread section 3418. As
can also be seen in FIGS. 60-63, the distal closure tube segment 3430 is
constrained for axial movement relative to the spine member 3420 by an
axial retainer pin 3450 that is received in an axial slot 3424 in the
distal end of the spine member 3420.

[0248] As indicated above, the anvil 2524 is open and closed by rotating
the proximal closure tube segment 3410. The variable pitch thread
arrangement permits the distal closure tube segment 3430 to be driven in
the distal direction "DD" at a first speed or rate by virtue of the
engagement between the lug 3442 and the proximal groove/thread section
3418. When the lug 3442 engages the distal groove/thread section 3416,
the distal closure tube segment 3430 will be driven in the distal
direction at a second speed or rate. Because the proximal groove/thread
section 3418 is coarser than the distal groove/thread segment 3416, the
first speed will be greater than the second speed.

[0249] In at least one embodiment, the tool mounting portion 3500 is
configured to receive a corresponding first rotary motion from the
robotic controller 1001 and convert that first rotary motion to a primary
rotary motion for rotating the rotatable proximal closure tube segment
3410 about a longitudinal tool axis LT-LT. As can be seen in FIG. 64, a
proximal end 3460 of the proximal closure tube segment 3410 is rotatably
supported within a cradle arrangement 3504 attached to a tool mounting
plate 3502 of the tool mounting portion 3500. A rotation gear 3462 is
formed on or attached to the proximal end 3460 of the closure tube
segment 3410 for meshing engagement with a rotation drive assembly 3470
that is operably supported on the tool mounting plate 3502. In at least
one embodiment, a rotation drive gear 3472 is coupled to a corresponding
first one of the driven discs or elements 1304 on the adapter side of the
tool mounting plate 3502 when the tool mounting portion 3500 is coupled
to the tool holder 1270. See FIGS. 22 and 64. The rotation drive assembly
3470 further comprises a rotary driven gear 3474 that is rotatably
supported on the tool mounting plate 3502 in meshing engagement with the
rotation gear 3462 and the rotation drive gear 3472. Application of a
first rotary control motion from the robotic controller 1001 through the
tool holder 1270 and the adapter 1240 to the corresponding driven element
1304 will thereby cause rotation of the rotation drive gear 3472 by
virtue of being operably coupled thereto. Rotation of the rotation drive
gear 3472 ultimately results in the rotation of the closure tube segment
3410 to open and close the anvil 3524 as described above.

[0250] As indicated above, the surgical end effector 3412 employs a
cutting instrument of the type and constructions described above. FIG. 64
illustrates one form of knife drive assembly 3480 for axially advancing a
knife bar 3492 that is attached to such cutting instrument. One form of
the knife drive assembly 3480 comprises a rotary drive gear 3482 that is
coupled to a corresponding third one of the driven discs or elements 1304
on the adapter side of the tool mounting plate 3502 when the tool drive
portion 3500 is coupled to the tool holder 1270. See FIGS. 22 and 64. The
knife drive assembly 3480 further comprises a first rotary driven gear
assembly 3484 that is rotatably supported on the tool mounting plate
5200. The first rotary driven gear assembly 3484 is in meshing engagement
with a third rotary driven gear assembly 3486 that is rotatably supported
on the tool mounting plate 3502 and which is in meshing engagement with a
fourth rotary driven gear assembly 3488 that is in meshing engagement
with a threaded portion 3494 of drive shaft assembly 3490 that is coupled
to the knife bar 3492. Rotation of the rotary drive gear 3482 in a second
rotary direction will result in the axial advancement of the drive shaft
assembly 3490 and knife bar 3492 in the distal direction "DD".
Conversely, rotation of the rotary drive gear 3482 in a secondary rotary
direction (opposite to the second rotary direction) will cause the drive
shaft assembly 3490 and the knife bar 3492 to move in the proximal
direction.

[0251] FIGS. 65-74 illustrate another surgical tool 3600 embodiment of the
present invention that may be employed in connection with a robotic
system 1000. As can be seen in FIG. 65, the tool 3600 includes an end
effector in the form of a disposable loading unit 3612. Various forms of
disposable loading units that may be employed in connection with tool
3600 are disclosed, for example, in U.S. Patent Application Publication
No. US 2009/0206131 A1, entitled "End Effector Arrangements For a
Surgical Cutting and Stapling Instrument", the disclosure of which is
herein incorporated by reference in its entirety.

[0252] In at least one form, the disposable loading unit 3612 includes an
anvil assembly 3620 that is supported for pivotal travel relative to a
carrier 3630 that operably supports a staple cartridge 3640 therein. A
mounting assembly 3650 is pivotally coupled to the cartridge carrier 3630
to enable the carrier 3630 to pivot about an articulation axis AA-AA
relative to a longitudinal tool axis LT-LT. Referring to FIG. 70,
mounting assembly 3650 includes upper and lower mounting portions 3652
and 3654. Each mounting portion includes a threaded bore 3656 on each
side thereof dimensioned to receive threaded bolts (not shown) for
securing the proximal end of carrier 3630 thereto. A pair of centrally
located pivot members 3658 extends between upper and lower mounting
portions via a pair of coupling members 3660 which engage a distal end of
a housing portion 3662. Coupling members 3660 each include an
interlocking proximal portion 3664 configured to be received in grooves
3666 formed in the proximal end of housing portion 3662 to retain
mounting assembly 3650 and housing portion 3662 in a longitudinally fixed
position in relation thereto.

[0253] In various forms, housing portion 3662 of disposable loading unit
3614 includes an upper housing half 3670 and a lower housing half 3672
contained within an outer casing 3674. The proximal end of housing half
3670 includes engagement nubs 3676 for releasably engaging an elongated
shaft 3700 and an insertion tip 3678. Nubs 3676 form a bayonet-type
coupling with the distal end of the elongated shaft 3700 which will be
discussed in further detail below. Housing halves 3670, 3672 define a
channel 3674 for slidably receiving axial drive assembly 3680. A second
articulation link 3690 is dimensioned to be slidably positioned within a
slot 3679 formed between housing halves 3670, 3672. A pair of blow out
plates 3691 are positioned adjacent the distal end of housing portion
3662 adjacent the distal end of axial drive assembly 3680 to prevent
outward bulging of drive assembly 3680 during articulation of carrier
3630.

[0254] In various embodiments, the second articulation link 3690 includes
at least one elongated metallic plate. Preferably, two or more metallic
plates are stacked to form link 3690. The proximal end of articulation
link 3690 includes a hook portion 3692 configured to engage first
articulation link 3710 extending through the elongated shaft 3700. The
distal end of the second articulation link 3690 includes a loop 3694
dimensioned to engage a projection formed on mounting assembly 3650. The
projection is laterally offset from pivot pin 3658 such that linear
movement of second articulation link 3690 causes mounting assembly 3650
to pivot about pivot pins 3658 to articulate the carrier 3630.

[0255] In various forms, axial drive assembly 3680 includes an elongated
drive beam 3682 including a distal working head 3684 and a proximal
engagement section 3685. Drive beam 3682 may be constructed from a single
sheet of material or, preferably, multiple stacked sheets. Engagement
section 3685 includes a pair of engagement fingers which are dimensioned
and configured to mountingly engage a pair of corresponding retention
slots formed in drive member 3686. Drive member 3686 includes a proximal
porthole 3687 configured to receive the distal end 3722 of control rod
2720 (See FIG. 74) when the proximal end of disposable loading unit 3614
is engaged with elongated shaft 3700 of surgical tool 3600.

[0256] Referring to FIGS. 65 and 72-74, to use the surgical tool 3600, a
disposable loading unit 3612 is first secured to the distal end of
elongated shaft 3700. It will be appreciated that the surgical tool 3600
may include an articulating or a non-articulating disposable loading
unit. To secure the disposable loading unit 3612 to the elongated shaft
3700, the distal end 3722 of control rod 3720 is inserted into insertion
tip 3678 of disposable loading unit 3612, and insertion tip 3678 is slid
longitudinally into the distal end of the elongated shaft 3700 in the
direction indicated by arrow "A" in FIG. 72 such that hook portion 3692
of second articulation link 3690 slides within a channel 3702 in the
elongated shaft 3700. Nubs 3676 will each be aligned in a respective
channel (not shown) in elongated shaft 3700. When hook portion 3692
engages the proximal wall 3704 of channel 3702, disposable loading unit
3612 is rotated in the direction indicated by arrow "B" in FIGS. 71 and
74 to move hook portion 3692 of second articulation link 3690 into
engagement with finger 3712 of first articulation link 3710. Nubs 3676
also form a "bayonet-type" coupling within annular channel 3703 in the
elongated shaft 3700. During rotation of loading unit 3612, nubs 3676
engage cam surface 3732 (FIG. 72) of block plate 3730 to initially move
plate 3730 in the direction indicated by arrow "C" in FIG. 72 to lock
engagement member 3734 in recess 3721 of control rod 3720 to prevent
longitudinal movement of control rod 3720 during attachment of disposable
loading unit 3612. During the final degree of rotation, nubs 3676
disengage from cam surface 3732 to allow blocking plate 3730 to move in
the direction indicated by arrow "D" in FIGS. 71 and 74 from behind
engagement member 3734 to once again permit longitudinal movement of
control rod 3720. While the above-described attachment method reflects
that the disposable loading unit 3612 is manipulated relative to the
elongated shaft 3700, the person of ordinary skill in the art will
appreciate that the disposable loading unit 3612 may be supported in a
stationary position and the robotic system 1000 may manipulate the
elongated shaft portion 3700 relative to the disposable loading unit 3612
to accomplish the above-described coupling procedure.

[0257]FIG. 75 illustrates another disposable loading unit 3612' that is
attachable in a bayonet-type arrangement with the elongated shaft 3700'
that is substantially identical to shaft 3700 except for the differences
discussed below. As can be seen in FIG. 75, the elongated shaft 3700' has
slots 3705 that extend for at least a portion thereof and which are
configured to receive nubs 3676 therein. In various embodiments, the
disposable loading unit 3612' includes arms 3677 extending therefrom
which, prior to the rotation of disposable loading unit 3612', can be
aligned, or at least substantially aligned, with nubs 3676 extending from
housing portion 3662. In at least one embodiment, arms 3677 and nubs 3676
can be inserted into slots 3705 in elongated shaft 3700', for example,
when disposable loading unit 3612' is inserted into elongated shaft
3700'. When disposable loading unit 3612' is rotated, arms 3677 can be
sufficiently confined within slots 3705 such that slots 3705 can hold
them in position, whereas nubs 3676 can be positioned such that they are
not confined within slots 3705 and can be rotated relative to arms 3677.
When rotated, the hook portion 3692 of the articulation link 3690 is
engaged with the first articulation link 3710 extending through the
elongated shaft 3700'.

[0258] Other methods of coupling the disposable loading units to the end
of the elongated shaft may be employed. For example, as shown in FIGS. 76
and 77, disposable loading unit 3612'' can include connector portion 3613
which can be configured to be engaged with connector portion 3740 of the
elongated shaft 3700''. In at least one embodiment, connector portion
3613 can include at least one projection and/or groove which can be mated
with at least one projection and/or groove of connector portion 3740. In
at least one such embodiment, the connector portions can include
co-operating dovetail portions. In various embodiments, the connector
portions can be configured to interlock with one another and prevent, or
at least inhibit, distal and/or proximal movement of disposable loading
unit 3612'' along axis 3741. In at least one embodiment, the distal end
of the axial drive assembly 3680' can include aperture 3681 which can be
configured to receive projection 3721 extending from control rod 3720'.
In various embodiments, such an arrangement can allow disposable loading
unit 3612'' to be assembled to elongated shaft 3700 in a direction which
is not collinear with or parallel to axis 3741. Although not illustrated,
axial drive assembly 3680' and control rod 3720 can include any other
suitable arrangement of projections and apertures to operably connect
them to each other. Also in this embodiment, the first articulation link
3710 which can be operably engaged with second articulation link 3690.

[0259] As can be seen in FIGS. 65 and 78, the surgical tool 3600 includes
a tool mounting portion 3750. The tool mounting portion 3750 includes a
tool mounting plate 3751 that is configured for attachment to the tool
drive assembly 1010. The tool mounting portion operably supported a
transmission arrangement 3752 thereon. In use, it may be desirable to
rotate the disposable loading unit 3612 about the longitudinal tool axis
defined by the elongated shaft 3700. In at least one embodiment, the
transmission arrangement 3752 includes a rotational transmission assembly
3753 that is configured to receive a corresponding rotary output motion
from the tool drive assembly 1010 of the robotic system 1000 and convert
that rotary output motion to a rotary control motion for rotating the
elongated shaft 3700 (and the disposable loading unit 3612) about the
longitudinal tool axis LT-LT. As can be seen in FIG. 78, a proximal end
3701 of the elongated shaft 3700 is rotatably supported within a cradle
arrangement 3754 that is attached to the tool mounting plate 3751 of the
tool mounting portion 3750. A rotation gear 3755 is formed on or attached
to the proximal end 3701 of the elongated shaft 3700 for meshing
engagement with a rotation gear assembly 3756 operably supported on the
tool mounting plate 3751. In at least one embodiment, a rotation drive
gear 3757 drivingly coupled to a corresponding first one of the driven
discs or elements 1304 on the adapter side of the tool mounting plate
3751 when the tool mounting portion 3750 is coupled to the tool drive
assembly 1010. The rotation transmission assembly 3753 further comprises
a rotary driven gear 3758 that is rotatably supported on the tool
mounting plate 3751 in meshing engagement with the rotation gear 3755 and
the rotation drive gear 3757. Application of a first rotary output motion
from the robotic system 1000 through the tool drive assembly 1010 to the
corresponding driven element 1304 will thereby cause rotation of the
rotation drive gear 3757 by virtue of being operably coupled thereto.
Rotation of the rotation drive gear 3757 ultimately results in the
rotation of the elongated shaft 3700 (and the disposable loading unit
3612) about the longitudinal tool axis LT-LT (primary rotary motion).

[0260] As can be seen in FIG. 78, a drive shaft assembly 3760 is coupled
to a proximal end of the control rod 2720. In various embodiments, the
control rod 2720 is axially advanced in the distal and proximal
directions by a knife/closure drive transmission 3762. One form of the
knife/closure drive assembly 3762 comprises a rotary drive gear 3763 that
is coupled to a corresponding second one of the driven rotatable body
portions, discs or elements 1304 on the adapter side of the tool mounting
plate 3751 when the tool mounting portion 3750 is coupled to the tool
holder 1270. The rotary driven gear 3763 is in meshing driving engagement
with a gear train, generally depicted as 3764. In at least one form, the
gear train 3764 further comprises a first rotary driven gear assembly
3765 that is rotatably supported on the tool mounting plate 3751. The
first rotary driven gear assembly 3765 is in meshing engagement with a
second rotary driven gear assembly 3766 that is rotatably supported on
the tool mounting plate 3751 and which is in meshing engagement with a
third rotary driven gear assembly 3767 that is in meshing engagement with
a threaded portion 3768 of the drive shaft assembly 3760. Rotation of the
rotary drive gear 3763 in a second rotary direction will result in the
axial advancement of the drive shaft assembly 3760 and control rod 2720
in the distal direction "DD". Conversely, rotation of the rotary drive
gear 3763 in a secondary rotary direction which is opposite to the second
rotary direction will cause the drive shaft assembly 3760 and the control
rod 2720 to move in the proximal direction. When the control rod 2720
moves in the distal direction, it drives the drive beam 3682 and the
working head 3684 thereof distally through the surgical staple cartridge
3640. As the working head 3684 is driven distally, it operably engages
the anvil 3620 to pivot it to a closed position.

[0261] The cartridge carrier 3630 may be selectively articulated about
articulation axis AA-AA by applying axial articulation control motions to
the first and second articulation links 3710 and 3690. In various
embodiments, the transmission arrangement 3752 further includes an
articulation drive 3770 that is operably supported on the tool mounting
plate 3751. More specifically and with reference to FIG. 78, it can be
seen that a proximal end portion 3772 of an articulation drive shaft 3771
configured to operably engage with the first articulation link 3710
extends through the rotation gear 3755 and is rotatably coupled to a
shifter rack gear 3774 that is slidably affixed to the tool mounting
plate 3751 through slots 3775. The articulation drive 3770 further
comprises a shifter drive gear 3776 that is coupled to a corresponding
third one of the driven discs or elements 1304 on the adapter side of the
tool mounting plate 3751 when the tool mounting portion 3750 is coupled
to the tool holder 1270. The articulation drive assembly 3770 further
comprises a shifter driven gear 3778 that is rotatably supported on the
tool mounting plate 3751 in meshing engagement with the shifter drive
gear 3776 and the shifter rack gear 3774. Application of a third rotary
output motion from the robotic system 1000 through the tool drive
assembly 1010 to the corresponding driven element 1304 will thereby cause
rotation of the shifter drive gear 3776 by virtue of being operably
coupled thereto. Rotation of the shifter drive gear 3776 ultimately
results in the axial movement of the shifter gear rack 3774 and the
articulation drive shaft 3771. The direction of axial travel of the
articulation drive shaft 3771 depends upon the direction in which the
shifter drive gear 3776 is rotated by the robotic system 1000. Thus,
rotation of the shifter drive gear 3776 in a first rotary direction will
result in the axial movement of the articulation drive shaft 3771 in the
proximal direction "PD" and cause the cartridge carrier 3630 to pivot in
a first direction about articulation axis AA-AA. Conversely, rotation of
the shifter drive gear 3776 in a second rotary direction (opposite to the
first rotary direction) will result in the axial movement of the
articulation drive shaft 3771 in the distal direction "DD" to thereby
cause the cartridge carrier 3630 to pivot about articulation axis AA-AA
in an opposite direction.

[0262]FIG. 79 illustrates yet another surgical tool 3800 embodiment of
the present invention that may be employed with a robotic system 1000. As
can be seen in FIG. 79, the surgical tool 3800 includes a surgical end
effector 3812 in the form of an endocutter 3814 that employs various
cable-driven components. Various forms of cable driven endocutters are
disclosed, for example, in U.S. Pat. No. 7,726,537, entitled "Surgical
Stapler With Universal Articulation and Tissue Pre-Clamp" and U.S. Patent
Application Publication No. US 2008/0308603A1, entitled "Cable Driven
Surgical Stapling and Cutting Instrument With Improved Cable Attachment
Arrangements", the disclosures of each are herein incorporated by
reference in their respective entireties. Such endocutters 3814 may be
referred to as a "disposable loading unit" because they are designed to
be disposed of after a single use. However, the various unique and novel
arrangements of various embodiments of the present invention may also be
employed in connection with cable driven end effectors that are reusable.

[0263] As can be seen in FIG. 79, in at least one form, the endocutter
3814 includes an elongated channel 3822 that operably supports a surgical
staple cartridge 3834 therein. An anvil 3824 is pivotally supported for
movement relative to the surgical staple cartridge 3834. The anvil 3824
has a cam surface 3825 that is configured for interaction with a
preclamping collar 3840 that is supported for axial movement relative
thereto. The end effector 3814 is coupled to an elongated shaft assembly
3808 that is attached to a tool mounting portion 3900. In various
embodiments, a closure cable 3850 is employed to move pre-clamping collar
3840 distally onto and over cam surface 3825 to close the anvil 3824
relative to the surgical staple cartridge 3834 and compress the tissue
therebetween. Preferably, closure cable 3850 attaches to the pre-clamping
collar 3840 at or near point 3841 and is fed through a passageway in
anvil 3824 (or under a proximal portion of anvil 3824) and fed proximally
through shaft 3808. Actuation of closure cable 3850 in the proximal
direction "PD" forces pre-clamping collar 3840 distally against cam
surface 3825 to close anvil 3824 relative to staple cartridge assembly
3834. A return mechanism, e.g., a spring, cable system or the like, may
be employed to return pre-clamping collar 3840 to a pre-clamping
orientation which re-opens the anvil 3824.

[0264] The elongated shaft assembly 3808 may be cylindrical in shape and
define a channel 3811 which may be dimensioned to receive a tube adapter
3870. See FIG. 80. In various embodiments, the tube adapter 3870 may be
slidingly received in friction-fit engagement with the internal channel
of elongated shaft 3808. The outer surface of the tube adapter 3870 may
further include at least one mechanical interface, e.g., a cutout or
notch 3871, oriented to mate with a corresponding mechanical interface,
e.g., a radially inwardly extending protrusion or detent (not shown),
disposed on the inner periphery of internal channel 3811 to lock the tube
adapter 3870 to the elongated shaft 3808. In various embodiments, the
distal end of tube adapter 3870 may include a pair of opposing flanges
3872a and 3872b which define a cavity for pivotably receiving a pivot
block 3873 therein. Each flange 3872a and 3872b may include an aperture
3874a and 3874b that is oriented to receive a pivot pin 3875 that extends
through an aperture in pivot block 3873 to allow pivotable movement of
pivot block 3873 about an axis that is perpendicular to longitudinal tool
axis "LT-LT". The channel 3822 may be formed with two upwardly extending
flanges 3823a, 3823b that have apertures therein, which are dimensioned
to receive a pivot pin 3827. In turn, pivot pin 3875 mounts through
apertures in pivot block 3873 to permit rotation of the surgical end
effector 3814 about the "Y" axis as needed during a given surgical
procedure. Rotation of pivot block 3873 about pin 3875 along "Z" axis
rotates the surgical end effector 3814 about the "Z" axis. See FIG. 80.
Other methods of fastening the elongated channel 3822 to the pivot block
3873 may be effectively employed without departing from the spirit and
scope of the present invention.

[0265] The surgical staple cartridge 3834 can be assembled and mounted
within the elongated channel 3822 during the manufacturing or assembly
process and sold as part of the surgical end effector 3812, or the
surgical staple cartridge 3834 may be designed for selective mounting
within the elongated channel 3822 as needed and sold separately, e.g., as
a single use replacement, replaceable or disposable staple cartridge
assembly. It is within the scope of this disclosure that the surgical end
effector 3812 may be pivotally, operatively, or integrally attached, for
example, to distal end 3809 of the elongated shaft assembly 3808 of a
disposable surgical stapler. As is known, a used or spent disposable
loading unit 3814 can be removed from the elongated shaft assembly 3808
and replaced with an unused disposable unit. The endocutter 3814 may also
preferably include an actuator, preferably a dynamic clamping member
3860, a sled 3862, as well as staple pushers (not shown) and staples (not
shown) once an unspent or unused cartridge 3834 is mounted in the
elongated channel 3822. See FIG. 80.

[0266] In various embodiments, the dynamic clamping member 3860 is
associated with, e.g., mounted on and rides on, or with or is connected
to or integral with and/or rides behind sled 3862. It is envisioned that
dynamic clamping member 3860 can have cam wedges or cam surfaces attached
or integrally formed or be pushed by a leading distal surface thereof. In
various embodiments, dynamic clamping member 3860 may include an upper
portion 3863 having a transverse aperture 3864 with a pin 3865 mountable
or mounted therein, a central support or upward extension 3866 and
substantially T-shaped bottom flange 3867 which cooperate to slidingly
retain dynamic clamping member 3860 along an ideal cutting path during
longitudinal, distal movement of sled 3862. The leading cutting edge
3868, here, knife blade 3869, is dimensioned to ride within slot 3835 of
staple cartridge assembly 3834 and separate tissue once stapled. As used
herein, the term "knife assembly" may include the aforementioned dynamic
clamping member 3860, knife 3869, and sled 3862 or other knife/beam/sled
drive arrangements and cutting instrument arrangements. In addition, the
various embodiments of the present invention may be employed with knife
assembly/cutting instrument arrangements that may be entirely supported
in the staple cartridge 3834 or partially supported in the staple
cartridge 3834 and elongated channel 3822 or entirely supported within
the elongated channel 3822.

[0267] In various embodiments, the dynamic clamping member 3860 may be
driven in the proximal and distal directions by a cable drive assembly
3870. In one non-limiting form, the cable drive assembly comprises a pair
of advance cables 3880, 3882 and a firing cable 3884. FIGS. 81 and 82
illustrate the cables 3880, 3882, 3884 in diagrammatic form. As can be
seen in those Figures, a first advance cable 3880 is operably supported
on a first distal cable transition support 3885 which may comprise, for
example, a pulley, rod, capstan, etc. that is attached to the distal end
of the elongated channel 3822 and a first proximal cable transition
support 3886 which may comprise, for example, a pulley, rod, capstan,
etc. that is operably supported by the elongated channel 3822. A distal
end 3881 of the first advance cable 3880 is affixed to the dynamic
clamping assembly 3860. The second advance cable 3882 is operably
supported on a second distal cable transition support 3887 which may, for
example, comprise a pulley, rod, capstan etc. that is mounted to the
distal end of the elongated channel 3822 and a second proximal cable
transition support 3888 which may, for example, comprise a pulley, rod,
capstan, etc. mounted to the proximal end of the elongated channel 3822.
The proximal end 3883 of the second advance cable 3882 may be attached to
the dynamic clamping assembly 3860. Also in these embodiments, an endless
firing cable 3884 is employed and journaled on a support 3889 that may
comprise a pulley, rod, capstan, etc. mounted within the elongated shaft
3808. In one embodiment, the retract cable 3884 may be formed in a loop
and coupled to a connector 3889' that is fixedly attached to the first
and second advance cables 3880, 3882.

[0268] Various non-limiting embodiments of the present invention include a
cable drive transmission 3920 that is operably supported on a tool
mounting plate 3902 of the tool mounting portion 3900. The tool mounting
portion 3900 has an array of electrical connecting pins 3904 which are
configured to interface with the slots 1258 (FIG. 21) in the adapter
1240'. Such arrangement permits the robotic system 1000 to provide
control signals to a control circuit 3910 of the tool 3800. While the
interface is described herein with reference to mechanical, electrical,
and magnetic coupling elements, it should be understood that a wide
variety of telemetry modalities might be used, including infrared,
inductive coupling, or the like.

[0269] Control circuit 3910 is shown in schematic form in FIG. 79. In one
form or embodiment, the control circuit 3910 includes a power supply in
the form of a battery 3912 that is coupled to an on-off solenoid powered
switch 3914. In other embodiments, however, the power supply may comprise
a source of alternating current. Control circuit 3910 further includes an
on/off solenoid 3916 that is coupled to a double pole switch 3918 for
controlling motor rotation direction. Thus, when the robotic system 1000
supplies an appropriate control signal, switch 3914 will permit battery
3912 to supply power to the double pole switch 3918. The robotic system
1000 will also supply an appropriate signal to the double pole switch
3918 to supply power to a shifter motor 3922.

[0270] Turning to FIGS. 83-88, at least one embodiment of the cable drive
transmission 3920 comprises a drive pulley 3930 that is operably mounted
to a drive shaft 3932 that is attached to a driven element 1304 of the
type and construction described above that is designed to interface with
a corresponding drive element 1250 of the adapter 1240. See FIGS. 18 and
84. Thus, when the tool mounting portion 3900 is operably coupled to the
tool holder 1270, the robot system 1000 can apply rotary motion to the
drive pulley 3930 in a desired direction. A first drive member or belt
3934 drivingly engages the drive pulley 3930 and a second drive shaft
3936 that is rotatably supported on a shifter yoke 3940. The shifter yoke
3940 is operably coupled to the shifter motor 3922 such that rotation of
the shaft 3923 of the shifter motor 3922 in a first direction will shift
the shifter yoke in a first direction "FD" and rotation of the shifter
motor shaft 3923 in a second direction will shift the shifter yoke 3940
in a second direction "SD". Other embodiments of the present invention
may employ a shifter solenoid arrangement for shifting the shifter yoke
in said first and second directions.

[0271] As can be seen in FIGS. 83-86, a closure drive gear 3950 mounted to
a second drive shaft 3936 and is configured to selectively mesh with a
closure drive assembly, generally designated as 3951. Likewise a firing
drive gear 3960 is also mounted to the second drive shaft 3936 and is
configured to selectively mesh with a firing drive assembly generally
designated as 3961. Rotation of the second drive shaft 3936 causes the
closure drive gear 3950 and the firing drive gear 3960 to rotate. In one
non-limiting embodiment, the closure drive assembly 3951 comprises a
closure driven gear 3952 that is coupled to a first closure pulley 3954
that is rotatably supported on a third drive shaft 3956. The closure
cable 3850 is drivingly received on the first closure pulley 3954 such
that rotation of the closure driven gear 3952 will drive the closure
cable 3850. Likewise, the firing drive assembly 3961 comprises a firing
driven gear 3962 that is coupled to a first firing pulley 3964 that is
rotatably supported on the third drive shaft 3956. The first and second
driving pulleys 3954 and 3964 are independently rotatable on the third
drive shaft 3956. The firing cable 3884 is drivingly received on the
first firing pulley 3964 such that rotation of the firing driven gear
3962 will drive the firing cable 3884.

[0272] Also in various embodiments, the cable drive transmission 3920
further includes a braking assembly 3970. In at least one embodiment, for
example, the braking assembly 3970 includes a closure brake 3972 that
comprises a spring arm 3973 that is attached to a portion of the
transmission housing 3971. The closure brake 3972 has a gear lug 3974
that is sized to engage the teeth of the closure driven gear 3952 as will
be discussed in further detail below. The braking assembly 3970 further
includes a firing brake 3976 that comprises a spring arm 3977 that is
attached to another portion of the transmission housing 3971. The firing
brake 3976 has a gear lug 3978 that is sized to engage the teeth of the
firing driven gear 3962.

[0273] At least one embodiment of the surgical tool 3800 may be used as
follows. The tool mounting portion 3900 is operably coupled to the
interface 1240 of the robotic system 1000. The controller or control unit
of the robotic system is operated to locate the tissue to be cut and
stapled between the open anvil 3824 and the staple cartridge 3834. When
in that initial position, the braking assembly 3970 has locked the
closure driven gear 3952 and the firing driven gear 3962 such that they
cannot rotate. That is, as shown in FIG. 84, the gear lug 3974 is in
locking engagement with the closure driven gear 3952 and the gear lug
3978 is in locking engagement with the firing driven gear 3962. Once the
surgical end effector 3814 has been properly located, the controller 1001
of the robotic system 1000 will provide a control signal to the shifter
motor 3922 (or shifter solenoid) to move the shifter yoke 3940 in the
first direction. As the shifter yoke 3940 is moved in the first
direction, the closure drive gear 3950 moves the gear lug 3974 out of
engagement with the closure driven gear 3952 as it moves into meshing
engagement with the closure driven gear 3952. As can be seen in FIG. 83,
when in that position, the gear lug 3978 remains in locking engagement
with the firing driven gear 3962 to prevent actuation of the firing
system. Thereafter, the robotic controller 1001 provides a first rotary
actuation motion to the drive pulley 3930 through the interface between
the driven element 1304 and the corresponding components of the tool
holder 1240. As the drive pulley 3930 is rotated in the first direction,
the closure cable 3850 is rotated to drive the preclamping collar 3840
into closing engagement with the cam surface 3825 of the anvil 3824 to
move it to the closed position thereby clamping the target tissue between
the anvil 3824 and the staple cartridge 3834. See FIG. 79. Once the anvil
3824 has been moved to the closed position, the robotic controller 1001
stops the application of the first rotary motion to the drive pulley
3930. Thereafter, the robotic controller 1001 may commence the firing
process by sending another control signal to the shifter motor 3922 (or
shifter solenoid) to cause the shifter yoke to move in the second
direction "SD" as shown in FIG. 94. As the shifter yoke 3940 is moved in
the second direction, the firing drive gear 3960 moves the gear lug 3978
out of engagement with the firing driven gear 3962 as it moves into
meshing engagement with the firing driven gear 3962. As can be seen in
FIG. 85, when in that position, the gear lug 3974 remains in locking
engagement with the closure driven gear 3952 to prevent actuation of the
closure system. Thereafter, the robotic controller 1001 is activated to
provide the first rotary actuation motion to the drive pulley 3930
through the interface between the driven element 1304 and the
corresponding components of the tool holder 1240. As the drive pulley
3930 is rotated in the first direction, the firing cable 3884 is rotated
to drive the dynamic clamping member 3860 in the distal direction "DD"
thereby firing the stapes and cutting the tissue clamped in the end
effector 3814. Once the robotic system 1000 determines that the dynamic
clamping member 3860 has reached its distal most position--either through
sensors or through monitoring the amount of rotary input applied to the
drive pulley 3930, the controller 1001 may then apply a second rotary
motion to the drive pulley 3930 to rotate the closure cable 3850 in an
opposite direction to cause the dynamic clamping member 3860 to be
retracted in the proximal direction "PD". Once the dynamic clamping
member has been retracted to the starting position, the application of
the second rotary motion to the drive pulley 3930 is discontinued.
Thereafter, the shifter motor 3922 (or shifter solenoid) is powered to
move the shifter yoke 3940 to the closure position (FIG. 83). Once the
closure drive gear 3950 is in meshing engagement with the closure driven
gear 3952, the robotic controller 1001 may once again apply the second
rotary motion to the drive pulley 3930. Rotation of the drive pulley 3930
in the second direction causes the closure cable 3850 to retract the
preclamping collar 3840 out of engagement with the cam surface 3825 of
the anvil 3824 to permit the anvil 3824 to move to an open position (by a
spring or other means) to release the stapled tissue from the surgical
end effector 3814.

[0274]FIG. 89 illustrates a surgical tool 4000 that employs a gear driven
firing bar 4092 as shown in FIGS. 90-92. This embodiment includes an
elongated shaft assembly 4008 that extends from a tool mounting portion
4100. The tool mounting portion 4100 includes a tool mounting plate 4102
that operable supports a transmission arrangement 4103 thereon. The
elongated shaft assembly 4008 includes a rotatable proximal closure tube
4010 that is rotatably journaled on a proximal spine member 4020 that is
rigidly coupled to the tool mounting plate 4102. The proximal spine
member 4020 has a distal end that is coupled to an elongated channel
portion 4022 of a surgical end effector 4012. The surgical effector 4012
may be substantially similar to surgical end effector 3412 described
above. In addition, the anvil 4024 of the surgical end effector 4012 may
be opened and closed by a distal closure tube 4030 that operably
interfaces with the proximal closure tube 4010. Distal closure tube 4030
is identical to distal closure tube 3430 described above. Similarly,
proximal closure tube 4010 is identical to proximal closure tube segment
3410 described above.

[0275] Anvil 4024 is opened and closed by rotating the proximal closure
tube 4010 in manner described above with respect to distal closure tube
3410. In at least one embodiment, the transmission arrangement comprises
a closure transmission, generally designated as 4011. As will be further
discussed below, the closure transmission 4011 is configured to receive a
corresponding first rotary motion from the robotic system 1000 and
convert that first rotary motion to a primary rotary motion for rotating
the rotatable proximal closure tube 4010 about the longitudinal tool axis
LT-LT. As can be seen in FIG. 92, a proximal end 4060 of the proximal
closure tube 4010 is rotatably supported within a cradle arrangement 4104
that is attached to a tool mounting plate 4102 of the tool mounting
portion 4100. A rotation gear 4062 is formed on or attached to the
proximal end 4060 of the closure tube segment 4010 for meshing engagement
with a rotation drive assembly 4070 that is operably supported on the
tool mounting plate 4102. In at least one embodiment, a rotation drive
gear 4072 is coupled to a corresponding first one of the driven discs or
elements 1304 on the adapter side of the tool mounting plate 4102 when
the tool mounting portion 4100 is coupled to the tool holder 1270. See
FIGS. 22 and 92. The rotation drive assembly 4070 further comprises a
rotary driven gear 4074 that is rotatably supported on the tool mounting
plate 4102 in meshing engagement with the rotation gear 4062 and the
rotation drive gear 4072. Application of a first rotary control motion
from the robotic system 1000 through the tool holder 1270 and the adapter
1240 to the corresponding driven element 1304 will thereby cause rotation
of the rotation drive gear 4072 by virtue of being operably coupled
thereto. Rotation of the rotation drive gear 4072 ultimately results in
the rotation of the closure tube segment 4010 to open and close the anvil
4024 as described above.

[0276] As indicated above, the end effector 4012 employs a cutting element
3860 as shown in FIGS. 90 and 91. In at least one non-limiting
embodiment, the transmission arrangement 4103 further comprises a knife
drive transmission that includes a knife drive assembly 4080. FIG. 92
illustrates one form of knife drive assembly 4080 for axially advancing
the knife bar 4092 that is attached to such cutting element using cables
as described above with respect to surgical tool 3800. In particular, the
knife bar 4092 replaces the firing cable 3884 employed in an embodiment
of surgical tool 3800. One form of the knife drive assembly 4080
comprises a rotary drive gear 4082 that is coupled to a corresponding
second one of the driven discs or elements 1304 on the adapter side of
the tool mounting plate 4102 when the tool mounting portion 4100 is
coupled to the tool holder 1270. See FIGS. 22 and 92. The knife drive
assembly 4080 further comprises a first rotary driven gear assembly 4084
that is rotatably supported on the tool mounting plate 4102. The first
rotary driven gear assembly 4084 is in meshing engagement with a third
rotary driven gear assembly 4086 that is rotatably supported on the tool
mounting plate 4102 and which is in meshing engagement with a fourth
rotary driven gear assembly 4088 that is in meshing engagement with a
threaded portion 4094 of drive shaft assembly 4090 that is coupled to the
knife bar 4092. Rotation of the rotary drive gear 4082 in a second rotary
direction will result in the axial advancement of the drive shaft
assembly 4090 and knife bar 4092 in the distal direction "DD".
Conversely, rotation of the rotary drive gear 4082 in a secondary rotary
direction (opposite to the second rotary direction) will cause the drive
shaft assembly 4090 and the knife bar 4092 to move in the proximal
direction. Movement of the firing bar 4092 in the proximal direction "PD"
will drive the cutting element 3860 in the distal direction "DD".
Conversely, movement of the firing bar 4092 in the distal direction "DD"
will result in the movement of the cutting element 3860 in the proximal
direction "PD".

[0277] FIGS. 93-99 illustrate yet another surgical tool 5000 that may be
effectively employed in connection with a robotic system 1000. In various
forms, the surgical tool 5000 includes a surgical end effector 5012 in
the form of a surgical stapling instrument that includes an elongated
channel 5020 and a pivotally translatable clamping member, such as an
anvil 5070, which are maintained at a spacing that assures effective
stapling and severing of tissue clamped in the surgical end effector
5012. As can be seen in FIG. 95, the elongated channel 5020 may be
substantially U-shaped in cross-section and be fabricated from, for
example, titanium, 203 stainless steel, 304 stainless steel, 416
stainless steel, 17-4 stainless steel, 17-7 stainless steel, 6061 or 7075
aluminum, chromium steel, ceramic, etc. A substantially U-shaped metal
channel pan 5022 may be supported in the bottom of the elongated channel
5020 as shown.

[0278] Various embodiments include an actuation member in the form of a
sled assembly 5030 that is operably supported within the surgical end
effector 5012 and axially movable therein between a starting position and
an ending position in response to control motions applied thereto. In
some forms, the metal channel pan 5022 has a centrally-disposed slot 5024
therein to movably accommodate a base portion 5032 of the sled assembly
5030. The base portion 5032 includes a foot portion 5034 that is sized to
be slidably received in a slot 5021 in the elongated channel 5020. See
FIG. 95. As can be seen in FIGS. 94, 95, 98, and 99, the base portion
5032 of sled assembly 5030 includes an axially extending threaded bore
5036 that is configured to be threadedly received on a threaded drive
shaft 5130 as will be discussed in further detail below. In addition, the
sled assembly 5030 includes an upstanding support portion 5038 that
supports a tissue cutting blade or tissue cutting instrument 5040. The
upstanding support portion 5038 terminates in a top portion 5042 that has
a pair of laterally extending retaining fins 5044 protruding therefrom.
As shown in FIG. 95, the fins 5044 are positioned to be received within
corresponding slots 5072 in anvil 5070. The fins 5044 and the foot 5034
serve to retain the anvil 5070 in a desired spaced closed position as the
sled assembly 5030 is driven distally through the tissue clamped within
the surgical end effector 5014. As can also be seen in FIGS. 97 and 99,
the sled assembly 5030 further includes a reciprocatably or sequentially
activatable drive assembly 5050 for driving staple pushers toward the
closed anvil 5070.

[0279] More specifically and with reference to FIGS. 95 and 96, the
elongated channel 5020 is configured to operably support a surgical
staple cartridge 5080 therein. In at least one form, the surgical staple
cartridge 5080 comprises a body portion 5082 that may be fabricated from,
for example, Vectra, Nylon (6/6 or 6/12) and include a centrally disposed
slot 5084 for accommodating the upstanding support portion 5038 of the
sled assembly 5030. See FIG. 95. These materials could also be filled
with glass, carbon, or mineral fill of 10%-40%. The surgical staple
cartridge 5080 further includes a plurality of cavities 5086 for movably
supporting lines or rows of staple-supporting pushers 5088 therein. The
cavities 5086 may be arranged in spaced longitudinally extending lines or
rows 5090, 5092, 5094, 5096. For example, the rows 5090 may be referred
to herein as first outboard rows. The rows 5092 may be referred to herein
as first inboard rows. The rows 5094 may be referred to as second inboard
rows and the rows 5096 may be referred to as second outboard rows. The
first inboard row 5090 and the first outboard row 5092 are located on a
first lateral side of the longitudinal slot 5084 and the second inboard
row 5094 and the second outboard row 5096 are located on a second lateral
side of the longitudinal slot 5084. The first staple pushers 5088 in the
first inboard row 5092 are staggered in relationship to the first staple
pushers 5088 in the first outboard row 5090. Similarly, the second staple
pushers 5088 in the second outboard row 5096 are staggered in
relationship to the second pushers 5088 in the second inboard row 5094.
Each pusher 5088 operably supports a surgical staple 5098 thereon.

[0280] In various embodiments, the sequentially-activatable or
reciprocatably--activatable drive assembly 5050 includes a pair of
outboard drivers 5052 and a pair of inboard drivers 5054 that are each
attached to a common shaft 5056 that is rotatably mounted within the base
5032 of the sled assembly 5030. The outboard drivers 5052 are oriented to
sequentially or reciprocatingly engage a corresponding plurality of
outboard activation cavities 5026 provided in the channel pan 5022.
Likewise, the inboard drivers 5054 are oriented to sequentially or
reciprocatingly engage a corresponding plurality of inboard activation
cavities 5028 provided in the channel pan 5022. The inboard activation
cavities 5028 are arranged in a staggered relationship relative to the
adjacent outboard activation cavities 5026. See FIG. 96. As can also be
seen in FIGS. 96 and 98, in at least one embodiment, the sled assembly
5030 further includes distal wedge segments 5060 and intermediate wedge
segments 5062 located on each side of the bore 5036 to engage the pushers
5088 as the sled assembly 5030 is driven distally in the distal direction
"DD". As indicated above, the sled assembly 5030 is threadedly received
on a threaded portion 5132 of a drive shaft 5130 that is rotatably
supported within the end effector 5012. In various embodiments, for
example, the drive shaft 5130 has a distal end 5134 that is supported in
a distal bearing 5136 mounted in the surgical end effector 5012. See
FIGS. 95 and 96.

[0281] In various embodiments, the surgical end effector 5012 is coupled
to a tool mounting portion 5200 by an elongated shaft assembly 5108. In
at least one embodiment, the tool mounting portion 5200 operably supports
a transmission arrangement generally designated as 5204 that is
configured to receive rotary output motions from the robotic system. The
elongated shaft assembly 5108 includes an outer closure tube 5110 that is
rotatable and axially movable on a spine member 5120 that is rigidly
coupled to a tool mounting plate 5201 of the tool mounting portion 5200.
The spine member 5120 also has a distal end 5122 that is coupled to the
elongated channel portion 5020 of the surgical end effector 5012.

[0282] In use, it may be desirable to rotate the surgical end effector
5012 about a longitudinal tool axis LT-LT defined by the elongated shaft
assembly 5008. In various embodiments, the outer closure tube 5110 has a
proximal end 5112 that is rotatably supported on the tool mounting plate
5201 of the tool drive portion 5200 by a forward support cradle 5203. The
proximal end 5112 of the outer closure tube 5110 is configured to
operably interface with a rotation transmission portion 5206 of the
transmission arrangement 5204. In various embodiments, the proximal end
5112 of the outer closure tube 5110 is also supported on a closure sled
5140 that is also movably supported on the tool mounting plate 5201. A
closure tube gear segment 5114 is formed on the proximal end 5112 of the
outer closure tube 5110 for meshing engagement with a rotation drive
assembly 5150 of the rotation transmission 5206. As can be seen in FIG.
93, the rotation drive assembly 5150, in at least one embodiment,
comprises a rotation drive gear 5152 that is coupled to a corresponding
first one of the driven discs or elements 1304 on the adapter side 1307
of the tool mounting plate 5201 when the tool drive portion 5200 is
coupled to the tool holder 1270. The rotation drive assembly 5150 further
comprises a rotary driven gear 5154 that is rotatably supported on the
tool mounting plate 5201 in meshing engagement with the closure tube gear
segment 5114 and the rotation drive gear 5152. Application of a first
rotary control motion from the robotic system 1000 through the tool
holder 1270 and the adapter 1240 to the corresponding driven element 1304
will thereby cause rotation of the rotation drive gear 5152. Rotation of
the rotation drive gear 5152 ultimately results in the rotation of the
elongated shaft assembly 5108 (and the end effector 5012) about the
longitudinal tool axis LT-LT (represented by arrow "R" in FIG. 93).

[0283] Closure of the anvil 5070 relative to the surgical staple cartridge
5080 is accomplished by axially moving the outer closure tube 5110 in the
distal direction "DD". Such axial movement of the outer closure tube 5110
may be accomplished by a closure transmission portion 5144 of the
transmission arrangement 5204. As indicated above, in various
embodiments, the proximal end 5112 of the outer closure tube 5110 is
supported by the closure sled 5140 which enables the proximal end 5112 to
rotate relative thereto, yet travel axially with the closure sled 5140.
In particular, as can be seen in FIG. 93, the closure sled 5140 has an
upstanding tab 5141 that extends into a radial groove 5115 in the
proximal end portion 5112 of the outer closure tube 5110. In addition, as
was described above, the closure sled 5140 is slidably mounted to the
tool mounting plate 5201. In various embodiments, the closure sled 5140
has an upstanding portion 5142 that has a closure rack gear 5143 formed
thereon. The closure rack gear 5143 is configured for driving engagement
with the closure transmission 5144.

[0284] In various forms, the closure transmission 5144 includes a closure
spur gear 5145 that is coupled to a corresponding second one of the
driven discs or elements 1304 on the adapter side 1307 of the tool
mounting plate 5201. Thus, application of a second rotary control motion
from the robotic system 1000 through the tool holder 1270 and the adapter
1240 to the corresponding second driven element 1304 will cause rotation
of the closure spur gear 5145 when the interface 1230 is coupled to the
tool mounting portion 5200. The closure transmission 5144 further
includes a driven closure gear set 5146 that is supported in meshing
engagement with the closure spur gear 5145 and the closure rack gear
5143. Thus, application of a second rotary control motion from the
robotic system 1000 through the tool holder 1270 and the adapter 1240 to
the corresponding second driven element 1304 will cause rotation of the
closure spur gear 5145 and ultimately drive the closure sled 5140 and the
outer closure tube 5110 axially. The axial direction in which the closure
tube 5110 moves ultimately depends upon the direction in which the second
driven element 1304 is rotated. For example, in response to one rotary
closure motion received from the robotic system 1000, the closure sled
5140 will be driven in the distal direction "DD" and ultimately the outer
closure tube 5110 will be driven in the distal direction as well. The
outer closure tube 5110 has an opening 5117 in the distal end 5116 that
is configured for engagement with a tab 5071 on the anvil 5070 in the
manners described above. As the outer closure tube 5110 is driven
distally, the proximal end 5116 of the closure tube 5110 will contact the
anvil 5070 and pivot it closed. Upon application of an "opening" rotary
motion from the robotic system 1000, the closure sled 5140 and outer
closure tube 5110 will be driven in the proximal direction "PD" and pivot
the anvil 5070 to the open position in the manners described above.

[0285] In at least one embodiment, the drive shaft 5130 has a proximal end
5137 that has a proximal shaft gear 5138 attached thereto. The proximal
shaft gear 5138 is supported in meshing engagement with a distal drive
gear 5162 attached to a rotary drive bar 5160 that is rotatably supported
with spine member 5120. Rotation of the rotary drive bar 5160 and
ultimately rotary drive shaft 5130 is controlled by a rotary knife
transmission 5207 which comprises a portion of the transmission
arrangement 5204 supported on the tool mounting plate 5210. In various
embodiments, the rotary knife transmission 5207 comprises a rotary knife
drive system 5170 that is operably supported on the tool mounting plate
5201. In various embodiments, the knife drive system 5170 includes a
rotary drive gear 5172 that is coupled to a corresponding third one of
the driven discs or elements 1304 on the adapter side of the tool
mounting plate 5201 when the tool drive portion 5200 is coupled to the
tool holder 1270. The knife drive system 5170 further comprises a first
rotary driven gear 5174 that is rotatably supported on the tool mounting
plate 5201 in meshing engagement with a second rotary driven gear 5176
and the rotary drive gear 5172. The second rotary driven gear 5176 is
coupled to a proximal end portion 5164 of the rotary drive bar 5160.

[0286] Rotation of the rotary drive gear 5172 in a first rotary direction
will result in the rotation of the rotary drive bar 5160 and rotary drive
shaft 5130 in a first direction. Conversely, rotation of the rotary drive
gear 5172 in a second rotary direction (opposite to the first rotary
direction) will cause the rotary drive bar 5160 and rotary drive shaft
5130 to rotate in a second direction 2400. Thus, rotation of the drive
shaft 2440 results in rotation of the drive sleeve 2400.

[0287] One method of operating the surgical tool 5000 will now be
described. The tool drive 5200 is operably coupled to the interface 1240
of the robotic system 1000. The controller 1001 of the robotic system
1000 is operated to locate the tissue to be cut and stapled between the
open anvil 5070 and the surgical staple cartridge 5080. Once the surgical
end effector 5012 has been positioned by the robot system 1000 such that
the target tissue is located between the anvil 5070 and the surgical
staple cartridge 5080, the controller 1001 of the robotic system 1000 may
be activated to apply the second rotary output motion to the second
driven element 1304 coupled to the closure spur gear 5145 to drive the
closure sled 5140 and the outer closure tube 5110 axially in the distal
direction to pivot the anvil 5070 closed in the manner described above.
Once the robotic controller 1001 determines that the anvil 5070 has been
closed by, for example, sensors in the surgical end effector 5012 and/or
the tool drive portion 5200, the robotic controller 1001 system may
provide the surgeon with an indication that signifies the closure of the
anvil. Such indication may be, for example, in the form of a light and/or
audible sound, tactile feedback on the control members, etc. Then the
surgeon may initiate the firing process. In alternative embodiments,
however, the robotic controller 1001 may automatically commence the
firing process.

[0288] To commence the firing process, the robotic controller applies a
third rotary output motion to the third driven disc or element 1304
coupled to the rotary drive gear 5172. Rotation of the rotary drive gear
5172 results in the rotation of the rotary drive bar 5160 and rotary
drive shaft 5130 in the manner described above. Firing and formation of
the surgical staples 5098 can be best understood from reference to FIGS.
94, 96, and 97. As the sled assembly 5030 is driven in the distal
direction "DD" through the surgical staple cartridge 5080, the distal
wedge segments 5060 first contact the staple pushers 5088 and start to
move them toward the closed anvil 5070. As the sled assembly 5030
continues to move distally, the outboard drivers 5052 will drop into the
corresponding activation cavity 5026 in the channel pan 5022. The
opposite end of each outboard driver 5052 will then contact the
corresponding outboard pusher 5088 that has moved up the distal and
intermediate wedge segments 5060, 5062. Further distal movement of the
sled assembly 5030 causes the outboard drivers 5052 to rotate and drive
the corresponding pushers 5088 toward the anvil 5070 to cause the staples
5098 supported thereon to be formed as they are driven into the anvil
5070. It will be understood that as the sled assembly 5030 moves
distally, the knife blade 5040 cuts through the tissue that is clamped
between the anvil and the staple cartridge. Because the inboard drivers
5054 and outboard drivers 5052 are attached to the same shaft 5056 and
the inboard drivers 5054 are radially offset from the outboard drivers
5052 on the shaft 5056, as the outboard drivers 5052 are driving their
corresponding pushers 5088 toward the anvil 5070, the inboard drivers
5054 drop into their next corresponding activation cavity 5028 to cause
them to rotatably or reciprocatingly drive the corresponding inboard
pushers 5088 towards the closed anvil 5070 in the same manner. Thus, the
laterally corresponding outboard staples 5098 on each side of the
centrally disposed slot 5084 are simultaneously formed together and the
laterally corresponding inboard staples 5098 on each side of the slot
5084 are simultaneously formed together as the sled assembly 5030 is
driven distally. Once the robotic controller 1001 determines that the
sled assembly 5030 has reached its distal most position--either through
sensors or through monitoring the amount of rotary input applied to the
drive shaft 5130 and/or the rotary drive bar 5160, the controller 1001
may then apply a third rotary output motion to the drive shaft 5130 to
rotate the drive shaft 5130 in an opposite direction to retract the sled
assembly 5030 back to its starting position. Once the sled assembly 5030
has been retracted to the starting position (as signaled by sensors in
the end effector 5012 and/or the tool drive portion 5200), the
application of the second rotary motion to the drive shaft 5130 is
discontinued. Thereafter, the surgeon may manually activate the anvil
opening process or it may be automatically commenced by the robotic
controller 1001. To open the anvil 5070, the second rotary output motion
is applied to the closure spur gear 5145 to drive the closure sled 5140
and the outer closure tube 5110 axially in the proximal direction. As the
closure tube 5110 moves proximally, the opening 5117 in the distal end
5116 of the closure tube 5110 contacts the tab 5071 on the anvil 5070 to
pivot the anvil 5070 to the open position. A spring may also be employed
to bias the anvil 5070 to the open position when the closure tube 5116
has been returned to the starting position. Again, sensors in the
surgical end effector 5012 and/or the tool mounting portion 5200 may
provide the robotic controller 1001 with a signal indicating that the
anvil 5070 is now open. Thereafter, the surgical end effector 5012 may be
withdrawn from the surgical site.

[0289] FIGS. 100-105 diagrammatically depict the sequential firing of
staples in a surgical tool assembly 5000' that is substantially similar
to the surgical tool assembly 5000 described above. In this embodiment,
the inboard and outboard drivers 5052', 5054' have a cam-like shape with
a cam surface 5053 and an actuator protrusion 5055 as shown in FIGS.
100-106. The drivers 5052', 5054' are journaled on the same shaft 5056'
that is rotatably supported by the sled assembly 5030'. In this
embodiment, the sled assembly 5030' has distal wedge segments 5060' for
engaging the pushers 5088. FIG. 100 illustrates an initial position of
two inboard or outboard drivers 5052', 5054' as the sled assembly 5030'
is driven in the distal direction "DD". As can be seen in that Figure,
the pusher 5088a has advanced up the wedge segment 5060' and has
contacted the driver 5052', 5054'. Further travel of the sled assembly
5030' in the distal direction causes the driver 5052', 5054' to pivot in
the "P" direction (FIG. 101) until the actuator portion 5055 contacts the
end wall 5029a of the activation cavity 5026, 5028 as shown in FIG. 102.
Continued advancement of the sled assembly 5030' in the distal direction
"DD" causes the driver 5052', 5054' to rotate in the "D" direction as
shown in FIG. 103. As the driver 5052', 5054' rotates, the pusher 5088a
rides up the cam surface 5053 to the final vertical position shown in
FIG. 104. When the pusher 5088a reaches the final vertical position shown
in FIGS. 104 and 105, the staple (not shown) supported thereon has been
driven into the staple forming surface of the anvil to form the staple.

[0290] FIGS. 107-112 illustrate a surgical end effector 5312 that may be
employed for example, in connection with the tool mounting portion 1300
and shaft 2008 described in detail above. In various forms, the surgical
end effector 5312 includes an elongated channel 5322 that is constructed
as described above for supporting a surgical staple cartridge 5330
therein. The surgical staple cartridge 5330 comprises a body portion 5332
that includes a centrally disposed slot 5334 for accommodating an
upstanding support portion 5386 of a sled assembly 5380. See FIGS.
107-109. The surgical staple cartridge body portion 5332 further includes
a plurality of cavities 5336 for movably supporting staple-supporting
pushers 5350 therein. The cavities 5336 may be arranged in spaced
longitudinally extending rows 5340, 5342, 5344, 5346. The rows 5340, 5342
are located on one lateral side of the longitudinal slot 5334 and the
rows 5344, 5346 are located on the other side of longitudinal slot 5334.
In at least one embodiment, the pushers 5350 are configured to support
two surgical staples 5352 thereon. In particular, each pusher 5350
located on one side of the elongated slot 5334 supports one staple 5352
in row 5340 and one staple 5352 in row 5342 in a staggered orientation.
Likewise, each pusher 5350 located on the other side of the elongated
slot 5334 supports one surgical staple 5352 in row 5344 and another
surgical staple 5352 in row 5346 in a staggered orientation. Thus, every
pusher 5350 supports two surgical staples 5352.

[0291] As can be further seen in FIGS. 107, 108, the surgical staple
cartridge 5330 includes a plurality of rotary drivers 5360. More
particularly, the rotary drivers 5360 on one side of the elongated slot
5334 are arranged in a single line 5370 and correspond to the pushers
5350 in lines 5340, 5342. In addition, the rotary drivers 5360 on the
other side of the elongated slot 5334 are arranged in a single line 5372
and correspond to the pushers 5350 in lines 5344, 5346. As can be seen in
FIG. 107, each rotary driver 5360 is rotatably supported within the
staple cartridge body 5332. More particularly, each rotary driver 5360 is
rotatably received on a corresponding driver shaft 5362. Each driver 5360
has an arcuate ramp portion 5364 formed thereon that is configured to
engage an arcuate lower surface 5354 formed on each pusher 5350. See FIG.
112. In addition, each driver 5360 has a lower support portion 5366
extend therefrom to slidably support the pusher 5360 on the channel 5322.
Each driver 5360 has a downwardly extending actuation rod 5368 that is
configured for engagement with a sled assembly 5380.

[0292] As can be seen in FIG. 109, in at least one embodiment, the sled
assembly 5380 includes a base portion 5382 that has a foot portion 5384
that is sized to be slidably received in a slot 5333 in the channel 5322.
See FIG. 107. The sled assembly 5380 includes an upstanding support
portion 5386 that supports a tissue cutting blade or tissue cutting
instrument 5388. The upstanding support portion 5386 terminates in a top
portion 5390 that has a pair of laterally extending retaining fins 5392
protruding therefrom. The fins 5392 are positioned to be received within
corresponding slots (not shown) in the anvil (not shown). As with the
above-described embodiments, the fins 5392 and the foot portion 5384
serve to retain the anvil (not shown) in a desired spaced closed position
as the sled assembly 5380 is driven distally through the tissue clamped
within the surgical end effector 5312. The upstanding support portion
5386 is configured for attachment to a knife bar 2200 (FIG. 28). The sled
assembly 5380 further has a horizontally-extending actuator plate 5394
that is shaped for actuating engagement with each of the actuation rods
5368 on the pushers 5360.

[0293] Operation of the surgical end effector 5312 will now be explained
with reference to FIGS. 107 and 108. As the sled assembly 5380 is driven
in the distal direction "DD" through the staple cartridge 5330, the
actuator plate 5394 sequentially contacts the actuation rods 5368 on the
pushers 5360. As the sled assembly 5380 continues to move distally, the
actuator plate 5394 sequentially contacts the actuator rods 5368 of the
drivers 5360 on each side of the elongated slot 5334. Such action causes
the drivers 5360 to rotate from a first unactuated position to an
actuated portion wherein the pushers 5350 are driven towards the closed
anvil. As the pushers 5350 are driven toward the anvil, the surgical
staples 5352 thereon are driven into forming contact with the underside
of the anvil. Once the robotic system 1000 determines that the sled
assembly 5080 has reached its distal most position through sensors or
other means, the control system of the robotic system 1000 may then
retract the knife bar and sled assembly 5380 back to the starting
position. Thereafter, the robotic control system may then activate the
procedure for returning the anvil to the open position to release the
stapled tissue.

[0294] FIGS. 113-117 depict one form of an automated reloading system
embodiment of the present invention, generally designated as 5500. In one
form, the automated reloading system 5500 is configured to replace a
"spent" surgical end effector component in a manipulatable surgical tool
portion of a robotic surgical system with a "new" surgical end effector
component. As used herein, the term "surgical end effector component" may
comprise, for example, a surgical staple cartridge, a disposable loading
unit or other end effector components that, when used, are spent and must
be replaced with a new component. Furthermore, the term "spent" means
that the end effector component has been activated and is no longer
useable for its intended purpose in its present state. For example, in
the context of a surgical staple cartridge or disposable loading unit,
the term "spent" means that at least some of the unformed staples that
were previously supported therein have been "fired" therefrom. As used
herein, the term "new" surgical end effector component refers to an end
effector component that is in condition for its intended use. In the
context of a surgical staple cartridge or disposable loading unit, for
example, the term "new" refers to such a component that has unformed
staples therein and which is otherwise ready for use.

[0295] In various embodiments, the automated reloading system 5500
includes a base portion 5502 that may be strategically located within a
work envelope 1109 of a robotic arm cart 1100 (FIG. 14) of a robotic
system 1000. As used herein, the term "manipulatable surgical tool
portion" collectively refers to a surgical tool of the various types
disclosed herein and other forms of surgical robotically-actuated tools
that are operably attached to, for example, a robotic arm cart 1100 or
similar device that is configured to automatically manipulate and actuate
the surgical tool. The term "work envelope" as used herein refers to the
range of movement of the manipulatable surgical tool portion of the
robotic system. FIG. 14 generally depicts an area that may comprise a
work envelope of the robotic arm cart 1100. Those of ordinary skill in
the art will understand that the shape and size of the work envelope
depicted therein is merely illustrative. The ultimate size, shape and
location of a work envelope will ultimately depend upon the construction,
range of travel limitations, and location of the manipulatable surgical
tool portion. Thus, the term "work envelope" as used herein is intended
to cover a variety of different sizes and shapes of work envelopes and
should not be limited to the specific size and shape of the sample work
envelope depicted in FIG. 14.

[0296] As can be seen in FIG. 113, the base portion 5502 includes a new
component support section or arrangement 5510 that is configured to
operably support at least one new surgical end effector component in a
"loading orientation". As used herein, the term "loading orientation"
means that the new end effector component is supported in such away so as
to permit the corresponding component support portion of the
manipulatable surgical tool portion to be brought into loading engagement
with (i.e., operably seated or operably attached to) the new end effector
component (or the new end effector component to be brought into loading
engagement with the corresponding component support portion of the
manipulatable surgical tool portion) without human intervention beyond
that which may be necessary to actuate the robotic system. As will be
further appreciated as the present Detailed Description proceeds, in at
least one embodiment, the preparation nurse will load the new component
support section before the surgery with the appropriate length and color
cartridges (some surgical staple cartridges may support certain sizes of
staples the size of which may be indicated by the color of the cartridge
body) required for completing the surgical procedure. However, no direct
human interaction is necessary during the surgery to reload the robotic
endocutter. In one form, the surgical end effector component comprises a
staple cartridge 2034 that is configured to be operably seated within a
component support portion (elongated channel) of any of the various other
end effector arrangements described above. For explanation purposes, new
(unused) cartridges will be designated as "2034a" and spent cartridges
will be designated as "2034b". The Figures depict cartridges 2034a, 2034b
designed for use with a surgical end effector 2012 that includes a
channel 2022 and an anvil 2024, the construction and operation of which
were discussed in detail above. Cartridges 2034a, 2034b are identical to
cartridges 2034 described above. In various embodiments, the cartridges
2034a, 2034b are configured to be snappingly retained (i.e., loading
engagement) within the channel 2022 of a surgical end effector 2012. As
the present Detailed Description proceeds, however, those of ordinary
skill in the art will appreciate that the unique and novel features of
the automated cartridge reloading system 5500 may be effectively employed
in connection with the automated removal and installation of other
cartridge arrangements without departing from the spirit and scope of the
present invention.

[0297] In the depicted embodiment, the term "loading orientation" means
that the distal tip portion 2035a of the a new surgical staple cartridge
2034a is inserted into a corresponding support cavity 5512 in the new
cartridge support section 5510 such that the proximal end portion 2037a
of the new surgical staple cartridge 2034a is located in a convenient
orientation for enabling the arm cart 1100 to manipulate the surgical end
effector 2012 into a position wherein the new cartridge 2034a may be
automatically loaded into the channel 2022 of the surgical end effector
2012. In various embodiments, the base 5502 includes at least one sensor
5504 which communicates with the control system 1003 of the robotic
controller 1001 to provide the control system 1003 with the location of
the base 5502 and/or the reload length and color doe each staged or new
cartridge 2034a.

[0298] As can also be seen in the Figures, the base 5502 further includes
a collection receptacle 5520 that is configured to collect spent
cartridges 2034b that have been removed or disengaged from the surgical
end effector 2012 that is operably attached to the robotic system 1000.
In addition, in one form, the automated reloading system 5500 includes an
extraction system 5530 for automatically removing the spent end effector
component from the corresponding support portion of the end effector or
manipulatable surgical tool portion without specific human intervention
beyond that which may be necessary to activate the robotic system. In
various embodiments, the extraction system 5530 includes an extraction
hook member 5532. In one form, for example, the extraction hook member
5532 is rigidly supported on the base portion 5502. In one embodiment,
the extraction hook member has at least one hook 5534 formed thereon that
is configured to hookingly engage the distal end 2035 of a spent
cartridge 2034b when it is supported in the elongated channel 2022 of the
surgical end effector 2012. In various forms, the extraction hook member
5532 is conveniently located within a portion of the collection
receptacle 5520 such that when the spent end effector component
(cartridge 2034b) is brought into extractive engagement with the
extraction hook member 5532, the spent end effector component (cartridge
2034b) is dislodged from the corresponding component support portion
(elongated channel 2022), and falls into the collection receptacle 5020.
Thus, to use this embodiment, the manipulatable surgical tool portion
manipulates the end effector attached thereto to bring the distal end
2035 of the spent cartridge 2034b therein into hooking engagement with
the hook 5534 and then moves the end effector in such a way to dislodge
the spent cartridge 2034b from the elongated channel 2022.

[0299] In other arrangements, the extraction hook member 5532 comprises a
rotatable wheel configuration that has a pair of diametrically-opposed
hooks 5334 protruding therefrom. See FIGS. 113 and 116. The extraction
hook member 5532 is rotatably supported within the collection receptacle
5520 and is coupled to an extraction motor 5540 that is controlled by the
controller 1001 of the robotic system. This form of the automated
reloading system 5500 may be used as follows. FIG. 115 illustrates the
introduction of the surgical end effector 2012 that is operably attached
to the manipulatable surgical tool portion 1200. As can be seen in that
Figure, the arm cart 1100 of the robotic system 1000 locates the surgical
end effector 2012 in the shown position wherein the hook end 5534 of the
extraction member 5532 hookingly engages the distal end 2035 of the spent
cartridge 2034b in the surgical end effector 2012. The anvil 2024 of the
surgical end effector 2012 is in the open position. After the distal end
2035 of the spent cartridge 2034b is engaged with the hook end 5532, the
extraction motor 5540 is actuated to rotate the extraction wheel 5532 to
disengage the spent cartridge 2034b from the channel 2022. To assist with
the disengagement of the spent cartridge 2034b from the channel 2022 (or
if the extraction member 5530 is stationary), the robotic system 1000 may
move the surgical end effector 2012 in an upward direction (arrow "U" in
FIG. 116). As the spent cartridge 2034b is dislodged from the channel
2022, the spent cartridge 2034b falls into the collection receptacle
5520. Once the spent cartridge 2034b has been removed from the surgical
end effector 2012, the robotic system 1000 moves the surgical end
effector 2012 to the position shown in FIG. 117.

[0300] In various embodiments, a sensor arrangement 5533 is located
adjacent to the extraction member 5532 that is in communication with the
controller 1001 of the robotic system 1000. The sensor arrangement 5533
may comprise a sensor that is configured to sense the presence of the
surgical end effector 2012 and, more particularly the tip 2035b of the
spent surgical staple cartridge 2034b thereof as the distal tip portion
2035b is brought into engagement with the extraction member 5532. In some
embodiments, the sensor arrangement 5533 may comprise, for example, a
light curtain arrangement. However, other forms of proximity sensors may
be employed. In such arrangement, when the surgical end effector 2012
with the spent surgical staple cartridge 2034b is brought into extractive
engagement with the extraction member 5532, the sensor senses the distal
tip 2035b of the surgical staple cartridge 2034b (e.g., the light curtain
is broken). When the extraction member 5532 spins and pops the surgical
staple cartridge 2034b loose and it falls into the collection receptacle
5520, the light curtain is again unbroken. Because the surgical end
effector 2012 was not moved during this procedure, the robotic controller
1001 is assured that the spent surgical staple cartridge 2034b has been
removed therefrom. Other sensor arrangements may also be successfully
employed to provide the robotic controller 1001 with an indication that
the spent surgical staple cartridge 2034b has been removed from the
surgical end effector 2012.

[0301] As can be seen in FIG. 117, the surgical end effector 2012 is
positioned to grasp a new surgical staple cartridge 2034a between the
channel 2022 and the anvil 2024. More specifically, as shown in FIGS. 114
and 117, each cavity 5512 has a corresponding upstanding pressure pad
5514 associated with it. The surgical end effector 2012 is located such
that the pressure pad 5514 is located between the new cartridge 2034a and
the anvil 2024. Once in that position, the robotic system 1000 closes the
anvil 2024 onto the pressure pad 5514 which serves to push the new
cartridge 2034a into snapping engagement with the channel 2022 of the
surgical end effector 2012. Once the new cartridge 2034a has been snapped
into position within the elongated channel 2022, the robotic system 1000
then withdraws the surgical end effector 2012 from the automated
cartridge reloading system 5500 for use in connection with performing
another surgical procedure.

[0302] FIGS. 118-122 depict another automated reloading system 5600 that
may be used to remove a spent disposable loading unit 3612 from a
manipulatable surgical tool arrangement 3600 (FIGS. 65-78) that is
operably attached to an arm cart 1100 or other portion of a robotic
system 1000 and reload a new disposable loading unit 3612 therein. As can
be seen in FIGS. 118 and 119, one form of the automated reloading system
5600 includes a housing 5610 that has a movable support assembly in the
form of a rotary carrousel top plate 5620 supported thereon which
cooperates with the housing 5610 to form a hollow enclosed area 5612. The
automated reloading system 5600 is configured to be operably supported
within the work envelop of the manipulatable surgical tool portion of a
robotic system as was described above. In various embodiments, the rotary
carrousel plate 5620 has a plurality of holes 5622 for supporting a
plurality of orientation tubes 5660 therein. As can be seen in FIGS. 119
and 120, the rotary carrousel plate 5620 is affixed to a spindle shaft
5624. The spindle shaft 5624 is centrally disposed within the enclosed
area 5612 and has a spindle gear 5626 attached thereto. The spindle gear
5626 is in meshing engagement with a carrousel drive gear 5628 that is
coupled to a carrousel drive motor 5630 that is in operative
communication with the robotic controller 1001 of the robotic system
1000.

[0303] Various embodiments of the automated reloading system 5600 may also
include a carrousel locking assembly, generally designated as 5640. In
various forms, the carrousel locking assembly 5640 includes a cam disc
5642 that is affixed to the spindle shaft 5624. The spindle gear 5626 may
be attached to the underside of the cam disc 5642 and the cam disc 5642
may be keyed onto the spindle shaft 5624. In alternative arrangements,
the spindle gear 5626 and the cam disc 5642 may be independently
non-rotatably affixed to the spindle shaft 5624. As can be seen in FIGS.
119 and 120, a plurality of notches 5644 are spaced around the perimeter
of the cam disc 5642. A locking arm 5648 is pivotally mounted within the
housing 5610 and is biased into engagement with the perimeter of the cam
disc 5642 by a locking spring 5649. As can be seen in FIG. 118, the outer
perimeter of the cam disc 5642 is rounded to facilitate rotation of the
cam disc 5642 relative to the locking arm 5648. The edges of each notch
5644 are also rounded such that when the cam disc 5642 is rotated, the
locking arm 5648 is cammed out of engagement with the notches 5644 by the
perimeter of the cam disc 5642.

[0304] Various forms of the automated reloading system 5600 are configured
to support a portable/replaceable tray assembly 5650 that is configured
to support a plurality of disposable loading units 3612 in individual
orientation tubes 5660. More specifically and with reference to FIGS. 119
and 120, the replaceable tray assembly 5650 comprises a tray 5652 that
has a centrally-disposed locator spindle 5654 protruding from the
underside thereof. The locator spindle 5654 is sized to be received
within a hollow end 5625 of spindle shaft 5624. The tray 5652 has a
plurality of holes 5656 therein that are configured to support an
orientation tube 5660 therein. Each orientation tube 5660 is oriented
within a corresponding hole 5656 in the replaceable tray assembly 5650 in
a desired orientation by a locating fin 5666 on the orientation tube 5660
that is designed to be received within a corresponding locating slot 5658
in the tray assembly 5650. In at least one embodiment, the locating fin
5666 has a substantially V-shaped cross-sectional shape that is sized to
fit within a V-shaped locating slot 5658. Such arrangement serves to
orient the orientation tube 5660 in a desired starting position while
enabling it to rotate within the hole 5656 when a rotary motion is
applied thereto. That is, when a rotary motion is applied to the
orientation tube 5660 the V-shaped locating fin 5666 will pop out of its
corresponding locating slot enabling the tube 5660 to rotate relative to
the tray 5652 as will be discussed in further detail below. As can also
be seen in FIGS. 118-120, the replaceable tray 5652 may be provided with
one or more handle portions 5653 to facilitate transport of the tray
assembly 5652 when loaded with orientation tubes 5660.

[0305] As can be seen in FIG. 122, each orientation tube 5660 comprises a
body portion 5662 that has a flanged open end 5664. The body portion 5662
defines a cavity 5668 that is sized to receive a portion of a disposable
loading unit 3612 therein. To properly orient the disposable loading unit
3612 within the orientation tube 5660, the cavity 5668 has a flat
locating surface 5670 formed therein. As can be seen in FIG. 122, the
flat locating surface 5670 is configured to facilitate the insertion of
the disposable loading unit into the cavity 5668 in a desired or
predetermined non-rotatable orientation. In addition, the end 5669 of the
cavity 5668 may include a foam or cushion material 5672 that is designed
to cushion the distal end of the disposable loading unit 3612 within the
cavity 5668. Also, the length of the locating surface may cooperate with
a sliding support member 3689 of the axial drive assembly 3680 of the
disposable loading unit 3612 to further locate the disposable loading
unit 3612 at a desired position within the orientation tube 5660.

[0306] The orientation tubes 5660 may be fabricated from Nylon,
polycarbonate, polyethylene, liquid crystal polymer, 6061 or 7075
aluminum, titanium, 300 or 400 series stainless steel, coated or painted
steel, plated steel, etc. and, when loaded in the replaceable tray 5662
and the locator spindle 5654 is inserted into the hollow end 5625 of
spindle shaft 5624, the orientation tubes 5660 extend through
corresponding holes 5662 in the carrousel top plate 5620. Each
replaceable tray 5662 is equipped with a location sensor 5663 that
communicates with the control system 1003 of the controller 1001 of the
robotic system 1000. The sensor 5663 serves to identify the location of
the reload system, and the number, length, color and fired status of each
reload housed in the tray. In addition, an optical sensor or sensors 5665
that communicate with the robotic controller 1001 may be employed to
sense the type/size/length of disposable loading units that are loaded
within the tray 5662.

[0307] Various embodiments of the automated reloading system 5600 further
include a drive assembly 5680 for applying a rotary motion to the
orientation tube 5660 holding the disposable loading unit 3612 to be
attached to the shaft 3700 of the surgical tool 3600 (collectively the
"manipulatable surgical tool portion") that is operably coupled to the
robotic system. The drive assembly 5680 includes a support yoke 5682 that
is attached to the locking arm 5648. Thus, the support yoke 5682 pivots
with the locking arm 5648. The support yoke 5682 rotatably supports a
tube idler wheel 5684 and a tube drive wheel 5686 that is driven by a
tube motor 5688 attached thereto. Tube motor 5688 communicates with the
control system 1003 and is controlled thereby. The tube idler wheel 5684
and tube drive wheel 5686 are fabricated from, for example, natural
rubber, sanoprene, isoplast, etc. such that the outer surfaces thereof
create sufficient amount of friction to result in the rotation of an
orientation tube 5660 in contact therewith upon activation of the tube
motor 5688. The idler wheel 5684 and tube drive wheel 5686 are oriented
relative to each other to create a cradle area 5687 therebetween for
receiving an orientation tube 5060 in driving engagement therein.

[0308] In use, one or more of the orientation tubes 5660 loaded in the
automated reloading system 5600 are left empty, while the other
orientation tubes 5660 may operably support a corresponding new
disposable loading unit 3612 therein. As will be discussed in further
detail below, the empty orientation tubes 5660 are employed to receive a
spent disposable loading unit 3612 therein.

[0309] The automated reloading system 5600 may be employed as follows
after the system 5600 is located within the work envelope of the
manipulatable surgical tool portion of a robotic system. If the
manipulatable surgical tool portion has a spent disposable loading unit
3612 operably coupled thereto, one of the orientation tubes 5660 that are
supported on the replaceable tray 5662 is left empty to receive the spent
disposable loading unit 3612 therein. If, however, the manipulatable
surgical tool portion does not have a disposable loading unit 3612
operably coupled thereto, each of the orientation tubes 5660 may be
provided with a properly oriented new disposable loading unit 3612.

[0310] As described hereinabove, the disposable loading unit 3612 employs
a rotary "bayonet-type" coupling arrangement for operably coupling the
disposable loading unit 3612 to a corresponding portion of the
manipulatable surgical tool portion. That is, to attach a disposable
loading unit 3612 to the corresponding portion of the manipulatable
surgical tool portion (3700--see FIG. 71, 72), a rotary installation
motion must be applied to the disposable loading unit 3612 and/or the
corresponding portion of the manipulatable surgical tool portion when
those components have been moved into loading engagement with each other.
Such installation motions are collectively referred to herein as "loading
motions". Likewise, to decouple a spent disposable loading unit 3612 from
the corresponding portion of the manipulatable surgical tool, a rotary
decoupling motion must be applied to the spent disposable loading unit
3612 and/or the corresponding portion of the manipulatable surgical tool
portion while simultaneously moving the spent disposable loading unit and
the corresponding portion of the manipulatable surgical tool away from
each other. Such decoupling motions are collectively referred to herein
as "extraction motions".

[0311] To commence the loading process, the robotic system 1000 is
activated to manipulate the manipulatable surgical tool portion and/or
the automated reloading system 5600 to bring the manipulatable surgical
tool portion into loading engagement with the new disposable loading unit
3612 that is supported in the orientation tube 5660 that is in driving
engagement with the drive assembly 5680. Once the robotic controller 1001
(FIG. 13) of the robotic control system 1000 has located the
manipulatable surgical tool portion in loading engagement with the new
disposable loading unit 3612, the robotic controller 1001 activates the
drive assembly 5680 to apply a rotary loading motion to the orientation
tube 5660 in which the new disposable loading unit 3612 is supported
and/or applies another rotary loading motion to the corresponding portion
of the manipulatable surgical tool portion. Upon application of such
rotary loading motions(s), the robotic controller 1001 also causes the
corresponding portion of the manipulatable surgical tool portion to be
moved towards the new disposable loading unit 3612 into loading
engagement therewith. Once the disposable loading unit 3612 is in loading
engagement with the corresponding portion of the manipulatable tool
portion, the loading motions are discontinued and the manipulatable
surgical tool portion may be moved away from the automated reloading
system 5600 carrying with it the new disposable loading unit 3612 that
has been operably coupled thereto.

[0312] To decouple a spent disposable loading unit 3612 from a
corresponding manipulatable surgical tool portion, the robotic controller
1001 of the robotic system manipulates the manipulatable surgical tool
portion so as to insert the distal end of the spent disposable loading
unit 3612 into the empty orientation tube 5660 that remains in driving
engagement with the drive assembly 5680. Thereafter, the robotic
controller 1001 activates the drive assembly 5680 to apply a rotary
extraction motion to the orientation tube 5660 in which the spent
disposable loading unit 3612 is supported and/or applies a rotary
extraction motion to the corresponding portion of the manipulatable
surgical tool portion. The robotic controller 1001 also causes the
manipulatable surgical tool portion to withdraw away from the spent
rotary disposable loading unit 3612. Thereafter the rotary extraction
motion(s) are discontinued.

[0313] After the spent disposable loading unit 3612 has been removed from
the manipulatable surgical tool portion, the robotic controller 1001 may
activate the carrousel drive motor 5630 to index the carrousel top plate
5620 to bring another orientation tube 5660 that supports a new
disposable loading unit 3612 therein into driving engagement with the
drive assembly 5680. Thereafter, the loading process may be repeated to
attach the new disposable loading unit 3612 therein to the portion of the
manipulatable surgical tool portion. The robotic controller 1001 may
record the number of disposable loading units that have been used from a
particular replaceable tray 5652. Once the controller 1001 determines
that all of the new disposable loading units 3612 have been used from
that tray, the controller 1001 may provide the surgeon with a signal
(visual and/or audible) indicating that the tray 5652 supporting all of
the spent disposable loading units 3612 must be replaced with a new tray
5652 containing new disposable loading units 3612.

[0314] FIGS. 123-128 depict another non-limiting embodiment of a surgical
tool 6000 of the present invention that is well-adapted for use with a
robotic system 1000 that has a tool drive assembly 1010 (FIG. 18) that is
operatively coupled to a master controller 1001 that is operable by
inputs from an operator (i.e., a surgeon). As can be seen in FIG. 123,
the surgical tool 6000 includes a surgical end effector 6012 that
comprises an endocutter. In at least one form, the surgical tool 6000
generally includes an elongated shaft assembly 6008 that has a proximal
closure tube 6040 and a distal closure tube 6042 that are coupled
together by an articulation joint 6100. The surgical tool 6000 is
operably coupled to the manipulator by a tool mounting portion, generally
designated as 6200. The surgical tool 6000 further includes an interface
6030 which may mechanically and electrically couple the tool mounting
portion 6200 to the manipulator in the various manners described in
detail above.

[0315] In at least one embodiment, the surgical tool 6000 includes a
surgical end effector 6012 that comprises, among other things, at least
one component 6024 that is selectively movable between first and second
positions relative to at least one other component 6022 in response to
various control motions applied to component 6024 as will be discussed in
further detail below to perform a surgical procedure. In various
embodiments, component 6022 comprises an elongated channel 6022
configured to operably support a surgical staple cartridge 6034 therein
and component 6024 comprises a pivotally translatable clamping member,
such as an anvil 6024. Various embodiments of the surgical end effector
6012 are configured to maintain the anvil 6024 and elongated channel 6022
at a spacing that assures effective stapling and severing of tissue
clamped in the surgical end effector 6012. Unless otherwise stated, the
end effector 6012 is similar to the surgical end effector 2012 described
above and includes a cutting instrument (not shown) and a sled (not
shown). The anvil 6024 may include a tab 6027 at its proximal end that
interacts with a component of the mechanical closure system (described
further below) to facilitate the opening of the anvil 6024. The elongated
channel 6022 and the anvil 6024 may be made of an electrically conductive
material (such as metal) so that they may serve as part of an antenna
that communicates with sensor(s) in the end effector, as described above.
The surgical staple cartridge 6034 could be made of a nonconductive
material (such as plastic) and the sensor may be connected to or disposed
in the surgical staple cartridge 6034, as was also described above.

[0316] As can be seen in FIG. 123, the surgical end effector 6012 is
attached to the tool mounting portion 6200 by the elongated shaft
assembly 6008 according to various embodiments. As shown in the
illustrated embodiment, the elongated shaft assembly 6008 includes an
articulation joint generally designated as 6100 that enables the surgical
end effector 6012 to be selectively articulated about a first tool
articulation axis AA1-AA1 that is substantially transverse to a
longitudinal tool axis LT-LT and a second tool articulation axis AA2-AA2
that is substantially transverse to the longitudinal tool axis LT-LT as
well as the first articulation axis AA1-AA1. See FIG. 124. In various
embodiments, the elongated shaft assembly 6008 includes a closure tube
assembly 6009 that comprises a proximal closure tube 6040 and a distal
closure tube 6042 that are pivotably linked by a pivot links 6044 and
6046. The closure tube assembly 6009 is movably supported on a spine
assembly generally designated as 6102.

[0317] As can be seen in FIG. 125, the proximal closure tube 6040 is
pivotally linked to an intermediate closure tube joint 6043 by an upper
pivot link 6044U and a lower pivot link 6044L such that the intermediate
closure tube joint 6043 is pivotable relative to the proximal closure
tube 6040 about a first closure axis CA1-CA1 and a second closure axis
CA2-CA2. In various embodiments, the first closure axis CA1-CA1 is
substantially parallel to the second closure axis CA2-CA2 and both
closure axes CA1-CA1, CA2-CA2 are substantially transverse to the
longitudinal tool axis LT-LT. As can be further seen in FIG. 134, the
intermediate closure tube joint 6043 is pivotally linked to the distal
closure tube 6042 by a left pivot link 6046L and a right pivot link 6046R
such that the intermediate closure tube joint 6043 is pivotable relative
to the distal closure tube 6042 about a third closure axis CA3-CA3 and a
fourth closure axis CA4-CA4. In various embodiments, the third closure
axis CA3-CA3 is substantially parallel to the fourth closure axis CA4-CA4
and both closure axes CA3-CA3, CA4-CA4 are substantially transverse to
the first and second closure axes CA1-CA1, CA2-CA2 as well as to
longitudinal tool axis LT-LT.

[0318] The closure tube assembly 6009 is configured to axially slide on
the spine assembly 6102 in response to actuation motions applied thereto.
The distal closure tube 6042 includes an opening 6045 which interfaces
with the tab 6027 on the anvil 6024 to facilitate opening of the anvil
6024 as the distal closure tube 6042 is moved axially in the proximal
direction "PD". The closure tubes 6040, 6042 may be made of electrically
conductive material (such as metal) so that they may serve as part of the
antenna, as described above. Components of the spine assembly 6102 may be
made of a nonconductive material (such as plastic).

[0319] As indicated above, the surgical tool 6000 includes a tool mounting
portion 6200 that is configured for operable attachment to the tool
mounting assembly 1010 of the robotic system 1000 in the various manners
described in detail above. As can be seen in FIG. 127, the tool mounting
portion 6200 comprises a tool mounting plate 6202 that operably supports
a transmission arrangement 6204 thereon. In various embodiments, the
transmission arrangement 6204 includes an articulation transmission 6142
that comprises a portion of an articulation system 6140 for articulating
the surgical end effector 6012 about a first tool articulation axis
TA1-TA1 and a second tool articulation axis TA2-TA2. The first tool
articulation axis TA1-TA1 is substantially transverse to the second tool
articulation axis TA2-TA2 and both of the first and second tool
articulation axes are substantially transverse to the longitudinal tool
axis LT-LT. See FIG. 124.

[0320] To facilitate selective articulation of the surgical end effector
6012 about the first and second tool articulation axes TA1-TA1, TA2-TA2,
the spine assembly 6102 comprises a proximal spine portion 6110 that is
pivotally coupled to a distal spine portion 6120 by pivot pins 6122 for
selective pivotal travel about TA1-TA1. Similarly, the distal spine
portion 6120 is pivotally attached to the elongated channel 6022 of the
surgical end effector 6012 by pivot pins 6124 to enable the surgical end
effector 6012 to selectively pivot about the second tool axis TA2-TA2
relative to the distal spine portion 6120.

[0321] In various embodiments, the articulation system 6140 further
includes a plurality of articulation elements that operably interface
with the surgical end effector 6012 and an articulation control
arrangement 6160 that is operably supported in the tool mounting member
6200 as will described in further detail below. In at least one
embodiment, the articulation elements comprise a first pair of first
articulation cables 6144 and 6146. The first articulation cables are
located on a first or right side of the longitudinal tool axis. Thus, the
first articulation cables are referred to herein as a right upper cable
6144 and a right lower cable 6146. The right upper cable 6144 and the
right lower cable 6146 extend through corresponding passages 6147, 6148,
respectively along the right side of the proximal spine portion 6110. See
FIG. 128. The articulation system 6140 further includes a second pair of
second articulation cables 6150, 6152. The second articulation cables are
located on a second or left side of the longitudinal tool axis. Thus, the
second articulation cables are referred to herein as a left upper
articulation cable 6150 and a left articulation cable 6152. The left
upper articulation cable 6150 and the left lower articulation cable 6152
extend through passages 6153, 6154, respectively in the proximal spine
portion 6110.

[0322] As can be seen in FIG. 124, the right upper cable 6144 extends
around an upper pivot joint 6123 and is attached to a left upper side of
the elongated channel 6022 at a left pivot joint 6125. The right lower
cable 6146 extends around a lower pivot joint 6126 and is attached to a
left lower side of the elongated channel 6022 at left pivot joint 6125.
The left upper cable 6150 extends around the upper pivot joint 6123 and
is attached to a right upper side of the elongated channel 6022 at a
right pivot joint 6127. The left lower cable 6152 extends around the
lower pivot joint 6126 and is attached to a right lower side of the
elongated channel 6022 at right pivot joint 6127. Thus, to pivot the
surgical end effector 6012 about the first tool articulation axis TA1-TA1
to the left (arrow "L"), the right upper cable 6144 and the right lower
cable 6146 must be pulled in the proximal direction "PD". To articulate
the surgical end effector 6012 to the right (arrow "R") about the first
tool articulation axis TA1-TA1, the left upper cable 6150 and the left
lower cable 6152 must be pulled in the proximal direction "PD". To
articulate the surgical end effector 6012 about the second tool
articulation axis TA2-TA2, in an upward direction (arrow "U"), the right
upper cable 6144 and the left upper cable 6150 must be pulled in the
proximal direction "PD". To articulate the surgical end effector 6012 in
the downward direction (arrow "DW") about the second tool articulation
axis TA2-TA2, the right lower cable 6146 and the left lower cable 6152
must be pulled in the proximal direction "PD".

[0323] The proximal ends of the articulation cables 6144, 6146, 6150, 6152
are coupled to the articulation control arrangement 6160 which comprises
a ball joint assembly that is a part of the articulation transmission
6142. More specifically and with reference to FIG. 128, the ball joint
assembly 6160 includes a ball-shaped member 6162 that is formed on a
proximal portion of the proximal spine 6110. Movably supported on the
ball-shaped member 6162 is an articulation control ring 6164. As can be
further seen in FIG. 128, the proximal ends of the articulation cables
6144, 6146, 6150, 6152 are coupled to the articulation control ring 6164
by corresponding ball joint arrangements 6166. The articulation control
ring 6164 is controlled by an articulation drive assembly 6170. As can be
most particularly seen in FIG. 128, the proximal ends of the first
articulation cables 6144, 6146 are attached to the articulation control
ring 6164 at corresponding spaced first points 6149, 6151 that are
located on plane 6159. Likewise, the proximal ends of the second
articulation cables 6150, 6152 are attached to the articulation control
ring 6164 at corresponding spaced second points 6153, 6155 that are also
located along plane 6159. As the present Detailed Description proceeds,
those of ordinary skill in the art will appreciate that such cable
attachment configuration on the articulation control ring 6164
facilitates the desired range of articulation motions as the articulation
control ring 6164 is manipulated by the articulation drive assembly 6170.

[0324] In various forms, the articulation drive assembly 6170 comprises a
horizontal articulation assembly generally designated as 6171. In at
least one form, the horizontal articulation assembly 6171 comprises a
horizontal push cable 6172 that is attached to a horizontal gear
arrangement 6180. The articulation drive assembly 6170 further comprises
a vertically articulation assembly generally designated as 6173. In at
least one form, the vertical articulation assembly 6173 comprises a
vertical push cable 6174 that is attached to a vertical gear arrangement
6190. As can be seen in FIGS. 127 and 128, the horizontal push cable 6172
extends through a support plate 6167 that is attached to the proximal
spine portion 6110. The distal end of the horizontal push cable 6174 is
attached to the articulation control ring 6164 by a corresponding
ball/pivot joint 6168. The vertical push cable 6174 extends through the
support plate 6167 and the distal end thereof is attached to the
articulation control ring 6164 by a corresponding ball/pivot joint 6169.

[0325] The horizontal gear arrangement 6180 includes a horizontal driven
gear 6182 that is pivotally mounted on a horizontal shaft 6181 that is
attached to a proximal portion of the proximal spine portion 6110. The
proximal end of the horizontal push cable 6172 is pivotally attached to
the horizontal driven gear 6182 such that, as the horizontal driven gear
6172 is rotated about horizontal pivot axis HA, the horizontal push cable
6172 applies a first pivot motion to the articulation control ring 6164.
Likewise, the vertical gear arrangement 6190 includes a vertical driven
gear 6192 that is pivotally supported on a vertical shaft 6191 attached
to the proximal portion of the proximal spine portion 6110 for pivotal
travel about a vertical pivot axis VA. The proximal end of the vertical
push cable 6174 is pivotally attached to the vertical driven gear 6192
such that as the vertical driven gear 6192 is rotated about vertical
pivot axis VA, the vertical push cable 6174 applies a second pivot motion
to the articulation control ring 6164.

[0326] The horizontal driven gear 6182 and the vertical driven gear 6192
are driven by an articulation gear train 6300 that operably interfaces
with an articulation shifter assembly 6320. In at least one form, the
articulation shifter assembly comprises an articulation drive gear 6322
that is coupled to a corresponding one of the driven discs or elements
1304 on the adapter side 1307 of the tool mounting plate 6202. See FIG.
22. Thus, application of a rotary input motion from the robotic system
1000 through the tool drive assembly 1010 to the corresponding driven
element 1304 will cause rotation of the articulation drive gear 6322 when
the interface 1230 is coupled to the tool holder 1270. An articulation
driven gear 6324 is attached to a splined shifter shaft 6330 that is
rotatably supported on the tool mounting plate 6202. The articulation
driven gear 6324 is in meshing engagement with the articulation drive
gear 6322 as shown. Thus, rotation of the articulation drive gear 6322
will result in the rotation of the shaft 6330. In various forms, a
shifter driven gear assembly 6340 is movably supported on the splined
portion 6332 of the shifter shaft 6330.

[0327] In various embodiments, the shifter driven gear assembly 6340
includes a driven shifter gear 6342 that is attached to a shifter plate
6344. The shifter plate 6344 operably interfaces with a shifter solenoid
assembly 6350. The shifter solenoid assembly 6350 is coupled to
corresponding pins 6352 by conductors 6352. See FIG. 127. Pins 6352 are
oriented to electrically communicate with slots 1258 (FIG. 21) on the
tool side 1244 of the adaptor 1240. Such arrangement serves to
electrically couple the shifter solenoid assembly 6350 to the robotic
controller 1001. Thus, activation of the shifter solenoid 6350 will shift
the shifter driven gear assembly 6340 on the splined portion 6332 of the
shifter shaft 6330 as represented by arrow "S" in FIGS. 136 and 137.
Various embodiments of the articulation gear train 6300 further include a
horizontal gear assembly 6360 that includes a first horizontal drive gear
6362 that is mounted on a shaft 6361 that is rotatably attached to the
tool mounting plate 6202. The first horizontal drive gear 6362 is
supported in meshing engagement with a second horizontal drive gear 6364.
As can be seen in FIG. 128, the horizontal driven gear 6182 is in meshing
engagement with the distal face portion 6365 of the second horizontal
driven gear 6364.

[0328] Various embodiments of the articulation gear train 6300 further
include a vertical gear assembly 6370 that includes a first vertical
drive gear 6372 that is mounted on a shaft 6371 that is rotatably
supported on the tool mounting plate 6202. The first vertical drive gear
6372 is supported in meshing engagement with a second vertical drive gear
6374 that is concentrically supported with the second horizontal drive
gear 6364. The second vertical drive gear 6374 is rotatably supported on
the proximal spine portion 6110 for travel therearound. The second
horizontal drive gear 6364 is rotatably supported on a portion of said
second vertical drive gear 6374 for independent rotatable travel thereon.
As can be seen in FIG. 128, the vertical driven gear 6192 is in meshing
engagement with the distal face portion 6375 of the second vertical
driven gear 6374.

[0329] In various forms, the first horizontal drive gear 6362 has a first
diameter and the first vertical drive gear 6372 has a second diameter. As
can be seen in FIGS. 127 and 128, the shaft 6361 is not on a common axis
with shaft 6371. That is, the first horizontal driven gear 6362 and the
first vertical driven gear 6372 do not rotate about a common axis. Thus,
when the shifter gear 6342 is positioned in a center "locking" position
such that the shifter gear 6342 is in meshing engagement with both the
first horizontal driven gear 6362 and the first vertical drive gear 6372,
the components of the articulation system 6140 are locked in position.
Thus, the shiftable shifter gear 6342 and the arrangement of first
horizontal and vertical drive gears 6362, 6372 as well as the
articulation shifter assembly 6320 collectively may be referred to as an
articulation locking system, generally designated as 6380.

[0330] In use, the robotic controller 1001 of the robotic system 1000 may
control the articulation system 6140 as follows. To articulate the end
effector 6012 to the left about the first tool articulation axis TA1-TA1,
the robotic controller 1001 activates the shifter solenoid assembly 6350
to bring the shifter gear 6342 into meshing engagement with the first
horizontal drive gear 6362. Thereafter, the controller 1001 causes a
first rotary output motion to be applied to the articulation drive gear
6322 to drive the shifter gear in a first direction to ultimately drive
the horizontal driven gear 6182 in another first direction. The
horizontal driven gear 6182 is driven to pivot the articulation ring 6164
on the ball-shaped portion 6162 to thereby pull right upper cable 6144
and the right lower cable 6146 in the proximal direction "PD". To
articulate the end effector 6012 to the right about the first tool
articulation axis TA1-TA1, the robotic controller 1001 activates the
shifter solenoid assembly 6350 to bring the shifter gear 6342 into
meshing engagement with the first horizontal drive gear 6362. Thereafter,
the controller 1001 causes the first rotary output motion in an opposite
direction to be applied to the articulation drive gear 6322 to drive the
shifter gear 6342 in a second direction to ultimately drive the
horizontal driven gear 6182 in another second direction. Such actions
result in the articulation control ring 6164 moving in such a manner as
to pull the left upper cable 6150 and the left lower cable 6152 in the
proximal direction "PD". In various embodiments the gear ratios and
frictional forces generated between the gears of the vertical gear
assembly 6370 serve to prevent rotation of the vertical driven gear 6192
as the horizontal gear assembly 6360 is actuated.

[0331] To articulate the end effector 6012 in the upper direction about
the second tool articulation axis TA2-TA2, the robotic controller 1001
activates the shifter solenoid assembly 6350 to bring the shifter gear
6342 into meshing engagement with the first vertical drive gear 6372.
Thereafter, the controller 1001 causes the first rotary output motion to
be applied to the articulation drive gear 6322 to drive the shifter gear
6342 in a first direction to ultimately drive the vertical driven gear
6192 in another first direction. The vertical driven gear 6192 is driven
to pivot the articulation ring 6164 on the ball-shaped portion 6162 of
the proximal spine portion 6110 to thereby pull right upper cable 6144
and the left upper cable 6150 in the proximal direction "PD". To
articulate the end effector 6012 in the downward direction about the
second tool articulation axis TA2-TA2, the robotic controller 1001
activates the shifter solenoid assembly 6350 to bring the shifter gear
6342 into meshing engagement with the first vertical drive gear 6372.
Thereafter, the controller 1001 causes the first rotary output motion to
be applied in an opposite direction to the articulation drive gear 6322
to drive the shifter gear 6342 in a second direction to ultimately drive
the vertical driven gear 6192 in another second direction. Such actions
thereby cause the articulation control ring 6164 to pull the right lower
cable 6146 and the left lower cable 6152 in the proximal direction "PD".
In various embodiments, the gear ratios and frictional forces generated
between the gears of the horizontal gear assembly 6360 serve to prevent
rotation of the horizontal driven gear 6182 as the vertical gear assembly
6370 is actuated.

[0332] In various embodiments, a variety of sensors may communicate with
the robotic controller 1001 to determine the articulated position of the
end effector 6012. Such sensors may interface with, for example, the
articulation joint 6100 or be located within the tool mounting portion
6200. For example, sensors may be employed to detect the position of the
articulation control ring 6164 on the ball-shaped portion 6162 of the
proximal spine portion 6110. Such feedback from the sensors to the
controller 1001 permits the controller 1001 to adjust the amount of
rotation and the direction of the rotary output to the articulation drive
gear 6322. Further, as indicated above, when the shifter drive gear 6342
is centrally positioned in meshing engagement with the first horizontal
drive gear 6362 and the first vertical drive gear 6372, the end effector
6012 is locked in the articulated position. Thus, after the desired
amount of articulation has been attained, the controller 1001 may
activate the shifter solenoid assembly 6350 to bring the shifter gear
6342 into meshing engagement with the first horizontal drive gear 6362
and the first vertical drive gear 6372. In alternative embodiments, the
shifter solenoid assembly 6350 may be spring activated to the central
locked position.

[0333] In use, it may be desirable to rotate the surgical end effector
6012 about the longitudinal tool axis LT-LT. In at least one embodiment,
the transmission arrangement 6204 on the tool mounting portion includes a
rotational transmission assembly 6400 that is configured to receive a
corresponding rotary output motion from the tool drive assembly 1010 of
the robotic system 1000 and convert that rotary output motion to a rotary
control motion for rotating the elongated shaft assembly 6008 (and
surgical end effector 6012) about the longitudinal tool axis LT-LT. In
various embodiments, for example, a proximal end portion 6041 of the
proximal closure tube 6040 is rotatably supported on the tool mounting
plate 6202 of the tool mounting portion 6200 by a forward support cradle
6205 and a closure sled 6510 that is also movably supported on the tool
mounting plate 6202. In at least one form, the rotational transmission
assembly 6400 includes a tube gear segment 6402 that is formed on (or
attached to) the proximal end 6041 of the proximal closure tube 6040 for
operable engagement by a rotational gear assembly 6410 that is operably
supported on the tool mounting plate 6202. As can be seen in FIG. 136,
the rotational gear assembly 6410, in at least one embodiment, comprises
a rotation drive gear 6412 that is coupled to a corresponding second one
of the driven discs or elements 1304 on the adapter side 1307 of the tool
mounting plate 6202 when the tool mounting portion 6200 is coupled to the
tool drive assembly 1010. See FIG. 22. The rotational gear assembly 6410
further comprises a first rotary driven gear 6414 that is rotatably
supported on the tool mounting plate 6202 in meshing engagement with the
rotation drive gear 6412. The first rotary driven gear 6414 is attached
to a drive shaft 6416 that is rotatably supported on the tool mounting
plate 6202. A second rotary driven gear 6418 is attached to the drive
shaft 6416 and is in meshing engagement with tube gear segment 6402 on
the proximal closure tube 6040. Application of a second rotary output
motion from the tool drive assembly 1010 of the robotic system 1000 to
the corresponding driven element 1304 will thereby cause rotation of the
rotation drive gear 6412. Rotation of the rotation drive gear 6412
ultimately results in the rotation of the elongated shaft assembly 6008
(and the surgical end effector 6012) about the longitudinal tool axis
LT-LT. It will be appreciated that the application of a rotary output
motion from the tool drive assembly 1010 in one direction will result in
the rotation of the elongated shaft assembly 6008 and surgical end
effector 6012 about the longitudinal tool axis LT-LT in a first direction
and an application of the rotary output motion in an opposite direction
will result in the rotation of the elongated shaft assembly 6008 and
surgical end effector 6012 in a second direction that is opposite to the
first direction.

[0334] In at least one embodiment, the closure of the anvil 2024 relative
to the staple cartridge 2034 is accomplished by axially moving a closure
portion of the elongated shaft assembly 2008 in the distal direction "DD"
on the spine assembly 2049. As indicated above, in various embodiments,
the proximal end portion 6041 of the proximal closure tube 6040 is
supported by the closure sled 6510 which comprises a portion of a closure
transmission, generally depicted as 6512. As can be seen in FIG. 127, the
proximal end portion 6041 of the proximal closure tube portion 6040 has a
collar 6048 formed thereon. The closure sled 6510 is coupled to the
collar 6048 by a yoke 6514 that engages an annular groove 6049 in the
collar 6048. Such arrangement serves to enable the collar 6048 to rotate
about the longitudinal tool axis LT-LT while still being coupled to the
closure transmission 6512. In various embodiments, the closure sled 6510
has an upstanding portion 6516 that has a closure rack gear 6518 formed
thereon. The closure rack gear 6518 is configured for driving engagement
with a closure gear assembly 6520. See FIG. 127.

[0335] In various forms, the closure gear assembly 6520 includes a closure
spur gear 6522 that is coupled to a corresponding second one of the
driven discs or elements 1304 on the adapter side 1307 of the tool
mounting plate 6202. See FIG. 22. Thus, application of a third rotary
output motion from the tool drive assembly 1010 of the robotic system
1000 to the corresponding second driven element 1304 will cause rotation
of the closure spur gear 6522 when the tool mounting portion 6202 is
coupled to the tool drive assembly 1010. The closure gear assembly 6520
further includes a closure reduction gear set 6524 that is supported in
meshing engagement with the closure spur gear 6522 and the closure rack
gear 2106. Thus, application of a third rotary output motion from the
tool drive assembly 1010 of the robotic system 1000 to the corresponding
second driven element 1304 will cause rotation of the closure spur gear
6522 and the closure transmission 6512 and ultimately drive the closure
sled 6510 and the proximal closure tube 6040 axially on the proximal
spine portion 6110. The axial direction in which the proximal closure
tube 6040 moves ultimately depends upon the direction in which the third
driven element 1304 is rotated. For example, in response to one rotary
output motion received from the tool drive assembly 1010 of the robotic
system 1000, the closure sled 6510 will be driven in the distal direction
"DD" and ultimately drive the proximal closure tube 6040 in the distal
direction "DD". As the proximal closure tube 6040 is driven distally, the
distal closure tube 6042 is also driven distally by virtue of it
connection with the proximal closure tube 6040. As the distal closure
tube 6042 is driven distally, the end of the closure tube 6042 will
engage a portion of the anvil 6024 and cause the anvil 6024 to pivot to a
closed position. Upon application of an "opening" out put motion from the
tool drive assembly 1010 of the robotic system 1000, the closure sled
6510 and the proximal closure tube 6040 will be driven in the proximal
direction "PD" on the proximal spine portion 6110. As the proximal
closure tube 6040 is driven in the proximal direction "PD", the distal
closure tube 6042 will also be driven in the proximal direction "PD". As
the distal closure tube 6042 is driven in the proximal direction "PD",
the opening 6045 therein interacts with the tab 6027 on the anvil 6024 to
facilitate the opening thereof. In various embodiments, a spring (not
shown) may be employed to bias the anvil 6024 to the open position when
the distal closure tube 6042 has been moved to its starting position. In
various embodiments, the various gears of the closure gear assembly 6520
are sized to generate the necessary closure forces needed to
satisfactorily close the anvil 6024 onto the tissue to be cut and stapled
by the surgical end effector 6012. For example, the gears of the closure
transmission 6520 may be sized to generate approximately 70-120 pounds of
closure forces.

[0336] In various embodiments, the cutting instrument is driven through
the surgical end effector 6012 by a knife bar 6530. See FIG. 127. In at
least one form, the knife bar 6530 is fabricated with a joint arrangement
(not shown) and/or is fabricated from material that can accommodate the
articulation of the surgical end effector 6102 about the first and second
tool articulation axes while remaining sufficiently rigid so as to push
the cutting instrument through tissue clamped in the surgical end
effector 6012. The knife bar 6530 extends through a hollow passage 6532
in the proximal spine portion 6110.

[0337] In various embodiments, a proximal end 6534 of the knife bar 6530
is rotatably affixed to a knife rack gear 6540 such that the knife bar
6530 is free to rotate relative to the knife rack gear 6540. The distal
end of the knife bar 6530 is attached to the cutting instrument in the
various manners described above. As can be seen in FIG. 127, the knife
rack gear 6540 is slidably supported within a rack housing 6542 that is
attached to the tool mounting plate 6202 such that the knife rack gear
6540 is retained in meshing engagement with a knife drive transmission
portion 6550 of the transmission arrangement 6204. In various
embodiments, the knife drive transmission portion 6550 comprises a knife
gear assembly 6560. More specifically and with reference to FIG. 127, in
at least one embodiment, the knife gear assembly 6560 includes a knife
spur gear 6562 that is coupled to a corresponding fourth one of the
driven discs or elements 1304 on the adapter side 1307 of the tool
mounting plate 6202. See FIG. 22. Thus, application of another rotary
output motion from the robotic system 1000 through the tool drive
assembly 1010 to the corresponding fourth driven element 1304 will cause
rotation of the knife spur gear 6562. The knife gear assembly 6560
further includes a knife gear reduction set 6564 that includes a first
knife driven gear 6566 and a second knife drive gear 6568. The knife gear
reduction set 6564 is rotatably mounted to the tool mounting plate 6202
such that the first knife driven gear 6566 is in meshing engagement with
the knife spur gear 6562. Likewise, the second knife drive gear 6568 is
in meshing engagement with a third knife drive gear assembly 6570. As
shown in FIG. 127, the second knife driven gear 6568 is in meshing
engagement with a fourth knife driven gear 6572 of the third knife drive
gear assembly 6570. The fourth knife driven gear 6572 is in meshing
engagement with a fifth knife driven gear assembly 6574 that is in
meshing engagement with the knife rack gear 6540. In various embodiments,
the gears of the knife gear assembly 6560 are sized to generate the
forces needed to drive the cutting instrument through the tissue clamped
in the surgical end effector 6012 and actuate the staples therein. For
example, the gears of the knife gear assembly 6560 may be sized to
generate approximately 40 to 100 pounds of driving force. It will be
appreciated that the application of a rotary output motion from the tool
drive assembly 1010 in one direction will result in the axial movement of
the cutting instrument in a distal direction and application of the
rotary output motion in an opposite direction will result in the axial
travel of the cutting instrument in a proximal direction.

[0338] As can be appreciated from the foregoing description, the surgical
tool 6000 represents a vast improvement over prior robotic tool
arrangements. The unique and novel transmission arrangement employed by
the surgical tool 6000 enables the tool to be operably coupled to a tool
holder portion 1010 of a robotic system that only has four rotary output
bodies, yet obtain the rotary output motions therefrom to: (i) articulate
the end effector about two different articulation axes that are
substantially transverse to each other as well as the longitudinal tool
axis; (ii) rotate the end effector 6012 about the longitudinal tool axis;
(iii) close the anvil 6024 relative to the surgical staple cartridge 6034
to varying degrees to enable the end effector 6012 to be used to
manipulate tissue and then clamp it into position for cutting and
stapling; and (iv) firing the cutting instrument to cut through the
tissue clamped within the end effector 6012. The unique and novel shifter
arrangements of various embodiments of the present invention described
above enable two different articulation actions to be powered from a
single rotatable body portion of the robotic system.

[0339] The various embodiments of the present invention have been
described above in connection with cutting-type surgical instruments. It
should be noted, however, that in other embodiments, the inventive
surgical instrument disclosed herein need not be a cutting-type surgical
instrument, but rather could be used in any type of surgical instrument
including remote sensor transponders. For example, it could be a
non-cutting endoscopic instrument, a grasper, a stapler, a clip applier,
an access device, a drug/gene therapy delivery device, an energy device
using ultrasound, RF, laser, etc. In addition, the present invention may
be in laparoscopic instruments, for example. The present invention also
has application in conventional endoscopic and open surgical
instrumentation as well as robotic-assisted surgery.

[0340] FIG. 129 depicts use of various aspects of certain embodiments of
the present invention in connection with a surgical tool 7000 that has an
ultrasonically powered end effector 7012. The end effector 7012 is
operably attached to a tool mounting portion 7100 by an elongated shaft
assembly 7008. The tool mounting portion 7100 may be substantially
similar to the various tool mounting portions described hereinabove. In
one embodiment, the end effector 7012 includes an ultrasonically powered
jaw portion 7014 that is powered by alternating current or direct current
in a known manner. Such ultrasonically-powered devices are disclosed, for
example, in U.S. Pat. No. 6,783,524, entitled "Robotic Surgical Tool With
Ultrasound Cauterizing and Cutting Instrument", the entire disclosure of
which is herein incorporated by reference. In the illustrated embodiment,
a separate power cord 7020 is shown. It will be understood, however, that
the power may be supplied thereto from the robotic controller 1001
through the tool mounting portion 7100. The surgical end effector 7012
further includes a movable jaw 7016 that may be used to clamp tissue onto
the ultrasonic jaw portion 7014. The movable jaw portion 7016 may be
selectively actuated by the robotic controller 1001 through the tool
mounting portion 7100 in anyone of the various manners herein described.

[0341] FIG. 130 illustrates use of various aspects of certain embodiments
of the present invention in connection with a surgical tool 8000 that has
an end effector 8012 that comprises a linear stapling device. The end
effector 8012 is operably attached to a tool mounting portion 8100 by an
elongated shaft assembly 3700 of the type and construction describe
above. However, the end effector 8012 may be attached to the tool
mounting portion 8100 by a variety of other elongated shaft assemblies
described herein. In one embodiment, the tool mounting portion 8100 may
be substantially similar to tool mounting portion 3750. However, various
other tool mounting portions and their respective transmission
arrangements describe in detail herein may also be employed. Such linear
stapling head portions are also disclosed, for example, in U.S. Pat. No.
7,673,781, entitled "Surgical Stapling Device With Staple Driver That
Supports Multiple Wire Diameter Staples", the entire disclosure of which
is herein incorporated by reference.

[0342] Various sensor embodiments described in U.S. Patent Publication No.
2011/0062212 A1 to Shelton, IV et al., the disclosure of which is herein
incorporated by reference in its entirety, may be employed with many of
the surgical tool embodiments disclosed herein. As was indicated above,
the master controller 1001 generally includes master controllers
(generally represented by 1003) which are grasped by the surgeon and
manipulated in space while the surgeon views the procedure via a stereo
display 1002. See FIG. 13. The master controllers 1001 are manual input
devices which preferably move with multiple degrees of freedom, and which
often further have an actuatable handle for actuating the surgical tools.
Some of the surgical tool embodiments disclosed herein employ a motor or
motors in their tool drive portion to supply various control motions to
the tool's end effector. Such embodiments may also obtain additional
control motion(s) from the motor arrangement employed in the robotic
system components. Other embodiments disclosed herein obtain all of the
control motions from motor arrangements within the robotic system.

[0343] Such motor powered arrangements may employ various sensor
arrangements that are disclosed in the published US patent application
cited above to provide the surgeon with a variety of forms of feedback
without departing from the spirit and scope of the present invention. For
example, those master controller arrangements 1003 that employ a manually
actuatable firing trigger can employ run motor sensor(s) to provide the
surgeon with feedback relating to the amount of force applied to or being
experienced by the cutting member. The run motor sensor(s) may be
configured for communication with the firing trigger portion to detect
when the firing trigger portion has been actuated to commence the
cutting/stapling operation by the end effector. The run motor sensor may
be a proportional sensor such as, for example, a rheostat or variable
resistor. When the firing trigger is drawn in, the sensor detects the
movement, and sends an electrical signal indicative of the voltage (or
power) to be supplied to the corresponding motor. When the sensor is a
variable resistor or the like, the rotation of the motor may be generally
proportional to the amount of movement of the firing trigger. That is, if
the operator only draws or closes the firing trigger in a small amount,
the rotation of the motor is relatively low. When the firing trigger is
fully drawn in (or in the fully closed position), the rotation of the
motor is at its maximum. In other words, the harder the surgeon pulls on
the firing trigger, the more voltage is applied to the motor causing
greater rates of rotation. Other arrangements may provide the surgeon
with a feed back meter 1005 that may be viewed through the display 1002
and provide the surgeon with a visual indication of the amount of force
being applied to the cutting instrument or dynamic clamping member. Other
sensor arrangements may be employed to provide the master controller 1001
with an indication as to whether a staple cartridge has been loaded into
the end effector, whether the anvil has been moved to a closed position
prior to firing, etc.

[0344] In alternative embodiments, a motor-controlled interface may be
employed in connection with the controller 1001 that limit the maximum
trigger pull based on the amount of loading (e.g., clamping force,
cutting force, etc.) experienced by the surgical end effector. For
example, the harder it is to drive the cutting instrument through the
tissue clamped within the end effector, the harder it would be to
pull/actuate the activation trigger. In still other embodiments, the
trigger on the controller 1001 is arranged such that the trigger pull
location is proportionate to the end effector-location/condition. For
example, the trigger is only fully depressed when the end effector is
fully fired.

[0345] The devices disclosed herein can be designed to be disposed of
after a single use, or they can be designed to be used multiple times. In
either case, however, the device can be reconditioned for reuse after at
least one use. Reconditioning can include any combination of the steps of
disassembly of the device, followed by cleaning or replacement of
particular pieces, and subsequent reassembly. In particular, the device
can be disassembled, and any number of the particular pieces or parts of
the device can be selectively replaced or removed in any combination.
Upon cleaning and/or replacement of particular parts, the device can be
reassembled for subsequent use either at a reconditioning facility, or by
a surgical team immediately prior to a surgical procedure. Those skilled
in the art will appreciate that reconditioning of a device can utilize a
variety of techniques for disassembly, cleaning/replacement, and
reassembly. Use of such techniques, and the resulting reconditioned
device, are all within the scope of the present application.

[0346] Although the present invention has been described herein in
connection with certain disclosed embodiments, many modifications and
variations to those embodiments may be implemented. For example,
different types of end effectors may be employed. Also, where materials
are disclosed for certain components, other materials may be used. The
foregoing description and following claims are intended to cover all such
modification and variations.

[0347] Any patent, publication, or other disclosure material, in whole or
in part, that is said to be incorporated by reference herein is
incorporated herein only to the extent that the incorporated materials
does not conflict with existing definitions, statements, or other
disclosure material set forth in this disclosure. As such, and to the
extent necessary, the disclosure as explicitly set forth herein
supersedes any conflicting material incorporated herein by reference. Any
material, or portion thereof, that is said to be incorporated by
reference herein, but which conflicts with existing definitions,
statements, or other disclosure material set forth herein will only be
incorporated to the extent that no conflict arises between that
incorporated material and the existing disclosure material.